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AC MOTOR CONTROLLERS/ DISPLAY PANEL DESCRIPTION, CHECKS, ADJUSTMENTS, AND TROUBLESHOOTING J1.6-2.0XMT (J30-40ZT) [J160]

PART NO. 1554633

2200 SRM 1087

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. • Keep the unit clean and the working area clean and orderly. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

AC Motor Controllers/ Display Panel

Table of Contents

TABLE OF CONTENTS Description ........................................................................................................................................................... General ............................................................................................................................................................. Description ....................................................................................................................................................... AC Motors .................................................................................................................................................... ZAPI™ AC Motor Controller ...................................................................................................................... Principles of Operation ............................................................................................................................... Controller Thermal Management............................................................................................................... Controller Area Network (CANbus) ........................................................................................................... Discharging the Capacitors............................................................................................................................. AC Motor Controller Repair ................................................................................................................................ General ............................................................................................................................................................. Special Precautions ..................................................................................................................................... Thermal Sensors .............................................................................................................................................. Motor Controller, Replace ............................................................................................................................... Controller Checks and Adjustments ................................................................................................................... Function Parameters ........................................................................................................................................... General ............................................................................................................................................................. Function Parameter Descriptions ....................................................................................................................... Parameters....................................................................................................................................................... Top Speed Forward...................................................................................................................................... Top Speed Reverse....................................................................................................................................... Acceleration ................................................................................................................................................. Regen Braking ............................................................................................................................................. Auto Deceleration........................................................................................................................................ Extended Shift............................................................................................................................................. Pump Acceleration ...................................................................................................................................... Tilt/Auxiliary Pump Acceleration............................................................................................................... Low Lift Speed............................................................................................................................................. Maximum Lift Speed................................................................................................................................... Maximum Lowering Speed ......................................................................................................................... Tilt Speed ..................................................................................................................................................... 3rd Function ................................................................................................................................................ 3rd Function Speed ..................................................................................................................................... 4th Function ................................................................................................................................................ 4th Function Speed ..................................................................................................................................... Battery Voltage............................................................................................................................................ Lift Interrupt ............................................................................................................................................... BDI Adjustment (Early Models) ................................................................................................................. BDI Adjustment (Later Models) ................................................................................................................. BDI Decrement Time .................................................................................................................................. Service Reminder ...................................................................................................................................... Custom ....................................................................................................................................................... Restore Defaults ........................................................................................................................................ Calibration Parameters ..................................................................................................................................... Throttle Calibration ...................................................................................................................................... Steering Calibration ...................................................................................................................................... Display Panel ..................................................................................................................................................... General ........................................................................................................................................................... Premium Display Panel ............................................................................................................................ Standard Display Panel ............................................................................................................................ Display Functions and Features .......................................................................................................................

©2005 HYSTER COMPANY

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Table of Contents

AC Motor Controllers/ Display Panel

TABLE OF CONTENTS (Continued) Key-On Initialization..................................................................................................................................... Standard Display ........................................................................................................................................... Premium Display ........................................................................................................................................... Lift Truck Inspection Function ..................................................................................................................... Access to Service Functions .......................................................................................................................... Service Functions .......................................................................................................................................... Performance Modes ....................................................................................................................................... Battery Discharge Indication (BDI) ............................................................................................................. Hourmeter...................................................................................................................................................... Status Code List ............................................................................................................................................ Dash Display Service Menu Navigation ........................................................................................................... General ........................................................................................................................................................... Moving Through Menu Selections ................................................................................................................ Editing and Adding Information .................................................................................................................. ETACC Test ........................................................................................................................................................ Manual Hydraulics: ....................................................................................................................................... Electro-Hydraulics:........................................................................................................................................ Troubleshooting.................................................................................................................................................. General ........................................................................................................................................................... Status Codes .................................................................................................................................................. Controller Connector Pin Outs ................................................................................................................... Valve Driver Module (Electro-Hydraulic Valve Option) ............................................................................. Hydraulic Lever Console (Electro-Hydraulic Option Only) ...................................................................... Dash Display................................................................................................................................................ System Logic Diagrams............................................................................................................................... This section is for the following models: J1.6-2.0XMT (J30-40ZT) [J160]

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2200 SRM 1087

Description

Description GENERAL This section describes the ZAPI™ AC motor controller. See Figure 1. Procedures are outlined for controller safety, adjustments, troubleshooting, and repair. This section does not contain information about other electrical components. See the section Electrical System 2200 SRM 1078 and the section Electro-Hydraulic Control Valve 2000 SRM 1086.

Throughout this section, forward will refer to travel in the direction of the forks and left and right are determined by an operator sitting in the seat facing forward. See Figure 2.

DESCRIPTION AC Motors The AC motors are three-phase AC induction motors. They do not include motor brushes or commutators. An AC induction motor operates on three-phase AC power provided directly by the motor controller. The motor speed is controlled by the controller and can be changed by the frequency of the AC power presented to the motor. A speed sensor has been built into the rear motor bearing, which provides feedback to the motor controller, allowing software to continually monitor motor direction and revolutions per minute (RPMs). Using this software feedback, the AC motor control system can provide much better vehicle speed control than is available with DC SEM systems. The AC motors also have thermal sensors, continuously monitored by the motor controllers, embedded in the motor windings.

ZAPI™ AC Motor Controller Figure 1. AC Controller

The ZAPI™ controller comes in two versions. See Figure 3. The first version contains two inverters for controlling the dual traction motors and a contactor for the lift function. The second version contains two inverters for controlling both traction motors and a transistor controller to control a series DC pump motor. The ZAPI™ controller is a solid state AC motor controller utilizing MOSFET technology with microprocessor control. The basic dual motor control is capable of controlling two asynchronous AC induction motors simultaneously. The controller has direct control of the traction system, main contactor, and the electromagnetic parking brakes.

A. LEFT SIDE B. RIGHT SIDE

C. FORWARD TRAVEL

Figure 2. Truck Orientation

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Description

2200 SRM 1087 operation of the controller. One microprocessor is designated the master and controls the right traction motor and the majority of the logic functions for the controller. The other microprocessor is designated the slave and controls the left traction motor and performs fewer functions than the master. The controller has many programmable features, including maximum speed, acceleration rate, neutral braking, and brake current limit. The controller includes a full range of features, as well as diagnostic and setup capability. The controller contains two separate DC to AC inverters and the logic cards necessary to process input signals from various truck components. The controller uses these inputs to control the speed and direction of the dual traction motors. These components are all contained within a single housing located on the inside of the rear compartment cover. See Figure 4.

Figure 3. AC Controllers The controller software provides self diagnostics which are accessed by means of a personal computer (PC) with specialized ETACC software (see the section Troubleshooting and Adjustments Using the AC Controls Program (ETACC) 2200 SRM 1058 or the on-board Dash Display). The controller software features a Test Menu for monitoring controller inputs and outputs, a Diagnostic Menu for viewing fault code information, and a Programming Menu for customizing the truck performance. The self diagnostics monitor the traction motor, brake coil, main contactor coil, controller temperature, and internal logic functions. Troubleshoot fault codes generated by the controller self diagnostics by using the on-board dash display or a properly configured IBM™ compatible PC.

Principles of Operation The traction motor controllers convert DC power from the truck’s battery to three-phase AC power at the frequencies and current necessary to independently power each traction motor. Each AC induction motor provides feedback to the controller for speed, rotation direction, and temperature. The ZAPI™ AC motor controller uses two sophisticated microprocessors to control the logic and

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1. 2. 3. 4. 5. 6. 7. 8.

LH TRACTION MOTOR RH TRACTION MOTOR DASH DISPLAY HYDRAULIC VALVE CONTACTOR AND FUSE PANEL TRACTION CONTROLLER HYDRAULIC PUMP AND MOTOR STEERING PUMP AND MOTOR Figure 4. Component Location

2200 SRM 1087 The controller may also be equipped with an optional transistor pump motor controller. This transistor control is installed in a single housing along with the two inverters for powering the traction motors. The pump controller receives inputs from the hydraulic valve or the optional valve driver module. The pump motor will run at specific preset motor speeds when the manual control valve is installed. Motor speed is based on the hydraulic function selected.

Controller Thermal Management The motor controller is equipped with internal thermal sensors to protect the controller from a high temperature condition. At a temperature of 80 C (176 F), the controller will begin to reduce current to the traction circuit and slow the speed of the lift truck. If the controller temperature continues to rise, the traction current will be further reduced. If the temperature reaches 100 C (212 F), current to the traction circuit will be reduced to zero and the lift truck cannot travel. As the controller cools, traction will be restored. When the controller has cooled to 80 C (176 F), full traction speed will be available.

Controller Area Network (CANbus)

Description

WARNING DO NOT short across the motor controller terminals with a screwdriver or jumper wire. NOTE: Some lift trucks are equipped with a premium controller, which controls the hydraulic motor as well as the traction motors. 1. Discharge the capacitor in the controller by connecting a 200-ohm, 2-watt resistor across the controller’s BT+ and B terminals for 10 seconds using insulated jumper wires. See Figure 5. 2. On the premium controller, also connect the 200ohm, 2-watt resistor across the controller’s P+ and B terminals for 10 seconds using insulated jumper wires. See Figure 6. 3. Remove the 200-ohm, 2-watt resistor before reconnecting the battery. NOTE: There are no user-serviceable parts in the ZAPI™ controller. No attempt should be made to open, repair, or otherwise modify the controller. Doing so may damage the controller and will void the warranty.

The motor controller and the dash display are connected together with a CANbus communication system. When equipped with the optional electro-hydraulic valve, the valve, valve driver module, and the electro-hydraulic lever console also communicate with the ZAPI™ controller over the CANbus network. A PC with the appropriate service software can easily communicate with all system nodes by simply connecting to the CANbus. A special connector, located under the dash and next to the display, is configured specifically for this purpose.

DISCHARGING THE CAPACITORS WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent an electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component in the electrical compartment. Wear safety glasses. Make certain that the battery has been disconnected.

1. 2. 3. 4.

POSITIVE CONNECTION (BT+) NEGATIVE CONNECTION (B ) INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR Figure 5. Discharging the Capacitors Economy

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AC Motor Controller Repair

2200 SRM 1087 Legend for Figure 6 1. 2. 3. 4. 5.

POSITIVE CONNECTION (BT+) NEGATIVE CONNECTION (B ) INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR POSITIVE CONNECTION (P+)

Figure 6. Discharging the Capacitors Standard and Premium

AC Motor Controller Repair GENERAL There are NO internal parts of the controller that can be repaired. The controller must be replaced if an internal malfunction occurs. The motor controller, like other electronic devices, has temperature limits. These devices can be damaged if they get too hot. Normal maintenance will help prevent high-temperature conditions. Always make sure components are installed using silicon grease and that all heat sink surfaces are clean. Do not block cooling airflow.

Special Precautions WARNING To avoid injury and prevent electrical shock, perform the following steps before troubleshooting, adjustments, or repairs: Turn the key to the OFF position and disconnect the battery connector. Discharge the capacitors in the controller.

WARNING Some checks in this section must be done with the battery connected and power applied to the controller. When making these checks, make sure the drive wheels are raised from the floor.

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Make sure you disconnect the battery and separate the connector before you remove any power cables from the power terminals of the motor controller. The capacitor stores electrical energy and can cause injury if a person discharges a capacitor through parts of the body. AFTER the battery is disconnected and the key is in the OFF position, make sure you discharge the capacitors.

CAUTION To help prevent controller damage: ALWAYS disconnect the battery when servicing the controller. ALWAYS discharge the capacitors before performing any service. NEVER connect power to the motor controller when any power cable is disconnected. NEVER make a short circuit at any motor controller terminal to battery (+), battery ( ), or the frame. Check with the dealer for your lift truck before operating in an area with normal temperatures over 40 C (104 F) The lift truck motor controller may not operate at full power under these conditions.

2200 SRM 1087

Controller Checks and Adjustments

MOTOR CONTROLLER, REPLACE

CAUTION Never add any electrical component to the lift truck without approval from your Hyster dealer. Added electrical components can prevent operation and/or damage the motor controller. Never use steam to clean electronic components. In dusty areas, blow low pressure air over the controller to remove dust. In oily or greasy areas, a mild solution of detergent or denatured alcohol can be used to wash off the controller. Then use low pressure air to completely dry the controller.

Make sure the battery is disconnected and the capacitors are discharged. Replace the motor controller as described in the following procedure. 1. Tag and disconnect all wire harness connections and power wires from the controller. 2. Remove the mounting screws holding the controller to the rear compartment cover. Carefully remove the controller from the truck.

CAUTION Do not remove the screws that secure the cover of the controller.

CAUTION Do NOT operate the traction system at high speeds or rapidly change the direction of operation with the wheels raised. Motor controller damage can occur. Do not subject the controller to any high voltage (hipot or megger) testing. Use a lead acid battery with the voltage and ampere hour rating specified for the lift truck. Follow normal battery maintenance procedures, recharging before 80 percent discharged, with periodic equalizing charges.

THERMAL SENSORS The thermal sensors for the motors are embedded in the motor end head and are continuously monitored by the motor controller. They are part of the motor and cannot be repaired.

3. Ensure there is no dirt between the base of the controller and the mounting surface on the rear compartment cover. 4. Put an even coat of thermal grease on the base plate of the controller. Ensure there are no air spaces between the plate and the mounting surface of the rear compartment cover. The base plate of the controller must make full contact with the mounting surface. 5. Install the screws that fasten the controller to the rear compartment cover. 6. Reconnect all power wires and wire harness connections to the controller. 7. Calibrate steering and throttle inputs. See Calibration Parameters in this section.

Controller Checks and Adjustments All checks and adjustments to the controller can be done with a PC or through the dash display on the instrument panel. A PC can be connected to the CANbus via a connector on the main wiring harness near the bottom (backside) of the display panel. The following checks and adjustments may be made using a PC or the dash display:

• Check the system status codes in history. • Check the state of charge of the battery. • Check the hourmeter readings on the traction circuit and hydraulic pump controllers. • Monitor or adjust the register values for each function as shown in Function Parameters in this section.

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Function Parameters

2200 SRM 1087

Function Parameters GENERAL Memory elements within the controller are called registers. These registers can have electronic data stored in them to control an operation. The data stored in a register is called a parameter. A parameter is a measurement number that defines a lift truck function. A specific function parameter works with other function parameters to control the operation of the lift truck.

Some functions can be adjusted within the permitted range to change the lift truck operation for a specific application. Adjustment of a register to a number that is different than the factory settings is allowed, but follow the instructions carefully. Adjustments other than the factory settings will cause the lift truck to operate differently and can cause increased wear of parts. Table 2. Transistor Lift With Manual Valve Parameters

WARNING The parameter for each function has a value range so the motor controller can be used on different models of lift trucks. This variation is needed for lift trucks of different sizes and operating voltages. Adjustment of a function to the wrong number value for your lift truck model can cause the truck to operate differently than normal. This different operation of the truck can cause an injury. NOTE: Table 1, Table 2, and Table 3 show the default parameter setting for each control function that is adjustable by the user. The factory-set default parameters are the recommended settings for new units. These settings will give satisfactory performance for most applications.

Control Settings Transistor Lift With Manual Valve

Factory Defaults 36V

48V

1

1

Max Lift Speed

100

100

Low Lift Speed

40

30

Tilt Speed

58

40

3rd Function Speed

33

25

4th Function Speed

85

85

Pump Acceleration

Table 3. Transistor Lift With Electro-Hydraulic Valve Parameters

Table 1. Traction Parameters Control Settings Control Settings Traction

Factory Defaults

Transistor Lift With Electro-Hydraulic Valve

Factory Defaults 36V

48V

1

1

36V

48V

Battery Voltage

36

48

Max Lift Speed

100

100

Extended Shift

ON

ON

Max Lowering Speed

75

75

5

5

Tilt Speed

33

25

Top Speed Max FWD

128 Hz

140 Hz

3rd Function Max Speed

33

25

Top Speed Max REV

128 Hz

140 Hz

4th Function Max Speed

85

85

Regen Braking

7

7

3rd Function

0

0

Auto Deceleration

6

6

4th Function

3

3

BDI Adjustment

35

35

4

4

Lift Interrupt

1

1

Tilt/Auxiliary Pump Acceleration

Service Reminder

0

0

Custom

0

0

Acceleration

6

Pump Acceleration

2200 SRM 1087

Function Parameter Descriptions

Function Parameter Descriptions PARAMETERS WARNING If any of the parameter values are changed, the operators must be told that the lift truck will operate differently.

WARNING NEVER adjust any of the following parameters without using the procedures and settings given in this section. The following section contains descriptions for the different parameters. Access these parameters through the SETUP menu in the dash display or with the PC software.

Top Speed Forward

the load on the forks. Acceleration rates are also unaffected by lowering the top speed.

Acceleration (Range 0-9) This parameter setting determines the truck acceleration rate. The truck will accelerate at this rate regardless of the load on the forks, provided that the motor and control can deliver the required power. To increase the acceleration rate above the factory setting, the extended shift parameter will need to be disabled. To reduce the acceleration rate below the factory setting, the extended shift parameter may be enabled or disabled.

(Range 10-140 Hz)

Any increase in performance will decrease the battery shift life.

This parameter setting determines the top speed of the truck in the forward direction.

Regen Braking

To increase the top speed above the factory setting, the extended shift parameter will need to be disabled. To reduce the top speed below the factory setting, the extended shift parameter may be enabled or disabled. For speed limits slower than the normal truck speed, the top speed is the same regardless of the load on the forks. Acceleration rates are also unaffected by lowering the top speed.

Top Speed Reverse (Range 10-140 Hz) This parameter setting determines the top speed of the truck in the reverse direction. To increase the top speed above the factory setting, the extended shift parameter will need to be disabled. To reduce the top speed below the factory setting, the extended shift parameter may be enabled or disabled. For speed limits slower than the normal truck speed, the top speed is the same regardless of

(Range 0-9) This parameter setting determines the maximum deceleration rate when the accelerator pedal is fully depressed during regen braking. NOTE: The deceleration rate is less when the pedal is not fully depressed.

Auto Deceleration (Range 0-9) This parameter setting determines the maximum deceleration rate when the accelerator pedal is released. The strength of auto deceleration is a percentage of the regen braking strength. A setting of zero will turn off auto deceleration completely and a setting of nine will give auto deceleration the same strength as regen braking.

Extended Shift (0 or 1) (0 = Disable; 1 = Enable) This parameter setting enables or disables a preset motor performance program in the traction motor controller.

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Function Parameter Descriptions When enabled, this function provides a balance between truck performance and battery shift life that will meet the requirements of most applications. Truck acceleration and top speed will vary with the amount of load on the forks. When disabled, truck acceleration and top speed are determined by values set in the acceleration and top speed parameters. If the motor and controller can deliver the power, then the truck performance will not vary with the amount of load on the forks or the battery state of charge. Grade climbing speed will also improve because the motor controller will deliver maximum current. Any increase in performance will decrease the battery shift life.

Pump Acceleration (Range 0-9) This parameter setting determines the hydraulic pump motor acceleration rate. Increasing the setting will increase the speed of the motor.

Tilt/Auxiliary Pump Acceleration (Range 0-9) This parameter setting determines the hydraulic pump motor acceleration rate when using the tilt or auxiliary functions with the electro-hydraulic valve option.

Low Lift Speed (Range 36V = 25-65%) (Range 48V = 20-50%) This parameter setting determines the hydraulic pump motor low speed. This is used with transistor lift and the manual control valve. Increasing the setting will increase the speed of the hydraulic pump motor.

Maximum Lift Speed (Range 0-100%) This parameter setting determines the hydraulic pump motor high speed. High speed is used for maximum lift speed.

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2200 SRM 1087

Maximum Lowering Speed (Range 0-100%) This parameter setting determines the hydraulic pump motor speed during lowering. Increasing the setting will increase lowering speed.

Tilt Speed (Range 36V = 20-66%) (Range 48V = 15-50%) This parameter setting is used to set the hydraulic motor speed when the tilt function is selected. Increasing the setting will increase the speed of the hydraulic pump motor.

3rd Function (Range 0, 1, or 2) (0 = 3rd Function Without Interlock) (1 = 3rd Function With Interlock) (2 = 3rd Function With Push/Pull) This parameter is used to select the operation of the 3rd function mini-lever or joystick roller switch. Use selection 0 when using the 3rd function to control a non-clamping type attachment. Use selection 1 when using the 3rd function to control a clamping type attachment. Use selection 2 when using the 3rd function to control a push/pull attachment.

3rd Function Speed (Range 36V = 20-100%) (Range 48V = 15-75%) This parameter setting is used to set the hydraulic pump motor speed when the 3rd function hydraulic lever is actuated. Increasing the setting increases the speed of the hydraulic pump motor.

4th Function (Range 0, 1, 2, or 3) (0 = 4th Function Without Interlock) (1 = 4th Function With Interlock) (2 = 4th Function With Push/Pull) (3 = Default - No 4th Function) This parameter is used to select the operation of the 4th function mini-lever or joystick roller switch. Use selection 0 when using the 4th function to control a non-clamping type attachment. Use selection 1 when

2200 SRM 1087 using the 4th function to control a clamping type attachment. Use selection 2 when using the 4th function to control a push/pull attachment.

4th Function Speed (Range 36V = 0-100%) (Range 48V = 0-100%) This parameter setting is used to set the hydraulic pump motor speed when the 4th function hydraulic lever is actuated. Increasing the setting increases the speed of the hydraulic pump motor.

Battery Voltage (36V or 48V) This parameter setting is used to inform the master controller what voltage battery is installed in the truck. The battery choices are 36V or 48V.

Lift Interrupt (0 or 1) (0 = Disable; 1 = Enable) This parameter setting enables or disables the lift interrupt feature. The lift interrupt feature stops lift operation when the battery discharge indicator (BDI) reads empty to protect the battery from excessive discharge and possible damage. NOTE: Trucks are shipped from the factory with this feature enabled.

BDI Adjustment (Early Models) (Range - Single Digit 0-9) This parameter setting allows for adjustment to improve the accuracy of the battery discharge indicator in the dash display. Increasing the setting will increase the battery voltage or specific gravity when the gage shows empty. A setting of 2 is the recommended starting point for flooded cell batteries. A setting of 7 is the recommended starting point for maintenance-free batteries. Further adjustments may be used to fine tune the BDI accuracy.

Function Parameter Descriptions

BDI Adjustment (Later Models) (Range - First Digit 1-5) (Range - Second Digit 3-7) This parameter setting allows for adjustment to improve the accuracy of the battery discharge indicator in the dash display. This first digit adjusts the charged setting. Increasing the setting will increase the battery voltage or specific gravity required for the indicator to show full. If the indicator consistently reads low with fully charged batteries, decrease this setting. The second digit adjusts the discharged setting. Increasing the setting will increase the battery voltage or specific gravity level required for the indicator to show empty. If the indicator consistently shows lift interrupt too soon, decrease this setting. A setting of 35 is the recommended starting point for flooded batteries. A setting of 37 is the recommended starting point for maintenance-free batteries. Further adjustments may be used to fine-tune the BDI accuracy.

BDI Decrement Time This adjustment is used to compensate for duty cycles that involve nonstop operation where frequent pauses of more than 5 seconds do not occur (no drive, no hydraulic use). When the truck is finally stopped, turned OFF, and then restarted, some deviation in the BDI reading may occur. One of three things may happen to the BDI reading when the truck is restarted: 1. The BDI gage still reads within plus or minus one bar as it did when the truck was turned OFF. No adjustment is needed. 2. If the BDI gage changed downward more than one bar, this parameter should be set to a lower number. 3. If the BDI gage changed upward more than one bar, this parameter should be set to a higher number. This adjustment has little or no effect on the BDI accuracy when the truck is used in intermittent duty cycles that have frequent pauses in truck activity for greater than 5 seconds each time.

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Display Panel

2200 SRM 1087

Service Reminder

Custom

(Set Next Hourmeter)

(Range 0-100)

This can be used by the service technician to show a Status Code 99 when the truck is due for service.

This parameter setting is not used except for special functions required for special applications. Normally it is set to zero.

To use this feature, set this function to the hourmeter reading at which the service is to occur. When that hourmeter is reached, the dash display will display Status Code 99 for 10 seconds each time the key is turned ON. After 20 hours of operation, the truck will slow to half speed and the code will display continuously until the service is performed. After servicing, adjust the service reminder parameter to the next desired service time.

Restore Defaults This function is used to restore all parameter settings to the factory default settings shown in Table 1, Table 2, and Table 3.

Calibration Parameters THROTTLE CALIBRATION

STEERING CALIBRATION

Activating this parameter allows the controller to “learn” the voltage setting of the throttle assembly. The controller uses this information to control the lift truck speed. See the section Electrical System 2200 SRM 1078.

Activating this parameter allows the controller to “learn” the voltage setting of the steering feedback system. The controller uses this information to control the traction motors during turning operations. See the section Electrical System 2200 SRM 1078.

Display Panel GENERAL

Standard Display Panel

There are two dash display options, Standard and Premium. Both displays look identical. See Figure 7.

• Allows preassigned service passwords to control access to the service functions available through the display. • Provides the same comprehensive set of service functions using the mode buttons and LCD as the Premium Display.

Premium Display Panel • Allows preassigned user passwords to control driver access to the vehicle. • Provides four driving modes that are accessed through the key pad. • Allows preassigned service passwords to control access to the service functions available through the display. • Provides a comprehensive set of service functions, which are accessed through the mode buttons and liquid crystal display (LCD). • Allows access to the User Check List function.

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Standard and Premium display panels are interchangeable on the vehicle. Therefore, the display system can be easily upgraded or downgraded by changing the display panel.

2200 SRM 1087

Display Functions and Features

Figure 7. Standard and Premium Display Panel

Display Functions and Features KEY-ON INITIALIZATION

STANDARD DISPLAY

Upon turning the key to the ON position, the display sequentially lights the indicators, from left to right, located along the top of the display. See Figure 8.

Following the sequence given above, and as the seat belt light becomes illuminated, the LCD displays the BDI as a bar. See Figure 9. As the battery is discharged, the bar becomes shorter.

NOTE: The seat belt light will stay on whether the seat belt is fastened or not fastened. The indicator lights turn off sequentially, except for the seat belt light, which will remain lighted for approximately 10 seconds.

When the key is turned to the OFF position, the Hourglass indicator becomes illuminated, and the following hourmeter information is flashed on the LCD screen: Traction Hours for 3-4 seconds, followed by Pump Hours for 3-4 seconds, after which the display turns off and appears black. See Figure 10.

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Display Functions and Features

1. 2. 3. 4. 5. 6. 7.

2200 SRM 1087

HOURMETER INDICATOR WRENCH INDICATOR BATTERY INDICATOR BATTERY DISCHARGE INDICATOR (BDI) BRAKE FLUID LEVEL PARKING BRAKE FASTEN SEAT BELT

8. 9. 10. 11. 12. 13. 14.

LCD SCREEN STAR PUSH BUTTON PUSH BUTTON #1 PUSH BUTTON #2 PUSH BUTTON #3 PUSH BUTTON #4 PUSH BUTTON #5

Figure 8. Dash Display Legend for Figure 9 1. 2. 3. 4.

Figure 9. Battery Discharge Indicator

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4 SEGMENTS ADJACENT TO RED 4 SEGMENTS ADJACENT TO ORANGE 12 SEGMENTS ADJACENT TO GREEN BDI SHOWS APPROXIMATELY 65-70% CHARGE

2200 SRM 1087

Display Functions and Features

Figure 12. Display Screen (Premium Display)

LIFT TRUCK INSPECTION FUNCTION Figure 10. Traction/Pump Hours

PREMIUM DISPLAY Following the sequence given above, and as the seat belt light becomes illuminated, the LCD displays the prompt for the operator to enter a password if this function has been enabled. See Figure 11. If the password function is disabled, the display will bypass the password prompt. To enable the password function, see Troubleshooting and Adjustments Using the AC Controls Program (ETACC) 2200 SRM 1058, Enable/Disable Password and Lift Truck Inspection Functions.

If this function is turned on, the operator is prompted to answer a checklist of questions. The operator indicates a 1 for pass or a 4 for fail. If the operator indicates the vehicle passes the inspection, the display will show the previous information and the operator can drive the vehicle. If the operator indicates that the vehicle fails the inspection, Service Required will appear on the display screen, and the vehicle will only operate in Mode 1 until the required action is taken. See Figure 13.

Figure 13. Inspection Failure Screen

Figure 11. Password Prompt Screen Until a password is entered that agrees with a password stored in the dash display, the lift and traction systems are inoperative. Passwords may be entered directly into the dash display or by using the PC software program. A few seconds after the correct password has been entered, the BDI and performance mode are displayed and the vehicle can be operated. See Figure 12.

The inspection feature can be enabled with or without the password function enabled, depending upon the user’s preference. The inspection checklist feature, as with the password feature, may be set up using either the dash display or using a PC. The checklist must be enabled or disabled by a service technician. The following is the list of checks: • Check for leaks. • Check service brake. • Check park brake. • Check horn, lights, and reverse alarm. • Check gauges and warning lights. • Check tire condition and pressure. • Check hydraulic oil level.

13

Display Functions and Features

2200 SRM 1087

ACCESS TO SERVICE FUNCTIONS

SERVICE FUNCTIONS

All service functions are accessible from either Standard or Premium displays. The following functions are the same with either display version, except as noted in the following sections.

The following submenu functions are accessible from the main menu of service functions, described above. This includes the following vehicle setup values and control function settings. The control function settings are discussed further in Function Parameter Descriptions.

Once the vehicle is turned ON with the key switch and the initialization process has been completed, a service technician can gain access to the service functions by pressing the star button (*) twice within 3 seconds. NOTE: It is suggested that the factory set password, 55555, be changed prior to the lift truck being placed into service. The display will prompt the service technician for a five-digit password. See Figure 14. The default setting for the password is 55555. When a correct password is entered, the Service Features menu is displayed as follows: • Hourmeters • Software Versions • Password • Diagnostics • Setup

Figure 14. Password Request If no password is entered, the screen will automatically return to the start up screen after 20 seconds. The screen will also revert to the start up screen if an incorrect password is entered. The technician can scroll through the menu using the up [1] or down [2] arrows and select the desired function by pressing the [4] button. Each menu selection has a list of submenu functions. The submenus are viewed and items selected by scrolling through the menu in the same manner as described above. To exit a selected function and return to the previous function, press the [3] button. Pressing the [3] button multiple times will return the technician to the operator’s driving mode.

14

• View Hourmeter Secure Hourmeter Set Pump Hours Set Traction Hours • Software Version Master Slave Display Valve Driver (Electro-Hydraulic only) • Password Add Password Delete Password Edit Password Operator Password Truck Inspection NOTE: All indications in the diagnostic menu are shown as ON, OFF, (or a value i.e. volts, amps). ON is indicated by a one. OFF is indicated by a zero. • Diagnostic Error Log Run Diagnostics Left Trac Mtr Speed Left Trac Mtr Crrnt Left Trac Mtr Temp Right Trac Mtr Speed Right Trac Mtr Crrnt Right Trac Mtr Temp Steer Position Lift Transistor Control Pump Motor Voltage Pump Motor Current No Run Diagnostics Hood Switch Seat Belt Switch Seat Switch Forward Switch Reverse Switch Accelerator Start Brake Switch Brake Fluid Level Hydraulic Oil Level Pump Motor Brushes Pump Motor Temp Throttle Pot Volt

2200 SRM 1087 Steering Enable Manual with Transistor Control Lo Lift Switch Lift Switch Tilt Switch 3rd Function Switch 4th Function Switch Electro-Hydraulic Arm Rest Switch Lift Speed Lower Speed Tilt Forward Speed Tilt Back Speed 3rd Func In Speed 3rd Func Out Speed 4th Func In Speed 4th Func Out Speed Manual Hydraulic Switch • Setup Traction Settings Throttle Calibration Max Steer Right Max Steer Left Max Steer 0 Top Speed Forward Top Speed Reverse Acceleration Regen Braking Auto Deceleration Extended Shift Hydraulic Settings Manual with Transistor Controller Lift Pump Accel Tilt/Aux Pump Accel Lo Lift Speed Max Lift Speed Tilt Speed 3rd Function Speed 4th Function Speed Electro-Hydraulic 4th Function Installed Lift Pump Accel Tilt/Aux Pump Accel Max Lift Speed Lowering Max Speed Tilt Max Speed 3rd Function Max Speed 4th Function Max Speed 3rd Function 4th Function Manual No Parameters Will Display

Display Functions and Features Truck Settings Serial Number Battery Voltage Lift Interrupt Restore Defaults BDI Adjustment BDI Decrement Time Service Reminder Custom Language

PERFORMANCE MODES NOTE: Performance modes are not available on the Standard Dash display, and the factory configuration is equivalent to Mode 4. When equipped with the Premium Dash display, the following four operator-selectable performance modes are available. These modes are preconfigured from the factory as described below. Mode 4 provides the highest performance and Modes 1-3 are percentages of Mode 4. A service technician, using the dash display or connecting with the PC software, can revise the control settings and configure the top speed and acceleration of the vehicle. The relationship between Modes 1-4 remains constant and cannot be altered. With the premium display, the operator can change modes by pressing the numbered keys on the dash display. Any number can be selected at any time to change the performance mode. If the mode change is requested while the traction system is in operation, the requested change will not take effect until the accelerator pedal has been released to the neutral position. During this operation, the display will indicate Mode X Requested until the accelerator is released. If the password is enabled, the operator will be limited by the performance level set in the password function.

15

Display Functions and Features Mode 4 is the highest level of performance available to the operator, regardless of the performance setup in the control. For instance, if the control is configured to limit top speed less than maximum, then Mode 4 top speed is equal to the top speed set in the control. Three lower performance modes are available to the operator by using the buttons on the display. These lower performance settings are percentages of the highest performance available in Mode 4 as described below: • Mode 4 - This is the highest performance mode. Other modes are a lower percentage of Mode 4. • Mode 3 - Top speed is the same as Mode 4. Acceleration is 80 percent of Mode 4. • Mode 2 - Top speed is 80 percent of Mode 4. Acceleration is 70 percent of Mode 4. • Mode 1 - Top speed is 60 percent of Mode 4. Acceleration is 60 percent of Mode 4.

BATTERY DISCHARGE INDICATION (BDI) The AC control system includes a Battery Discharge Indicator (BDI) that provides indication of the battery state of charge. See Figure 15. The BDI feature is displayed to the operator on the dash display with a 20-segment bar that looks and functions the same as the current BDI. Lift truck operators will not need to learn a new BDI system. The BDI provides full functionality when used with a full range of batteries including: • Flooded cell, standard amp-hour batteries • Flooded cell, high amp-hour capacity batteries • Valve regulated (absorbed glass mat) maintenancefree batteries (VRLA)

2200 SRM 1087 the battery is 80 percent discharged. Although lift interrupt prevents lifting, low speed functions, such as tilt, remain operational to allow the operator to more easily remove the forks from the load and return to the battery charging area. When lift interrupt is initiated, it will remain in effect until the battery is disconnected and a recharged battery is reconnected to the lift truck. In order to reset the BDI function and allow lift truck operation, the recharged battery must have a state of charge that is 20 percent above the open cell voltage BDI setting. Two BDI adjustment features are provided via the control setup function, which is accessible via the dash display (service password required) or with the PC service software.

HOURMETER There are three different hourmeter functions. 1. Pump hours - accumulates time only when the pump motor is operating. 2. Traction hours - accumulates time when the seat switch is closed and the key switch is in the ON position. 3. Secure hours - based on traction hours. The secure hours cannot be manually reset. However, secure hours will be automatically reset to zero if both the controller and the dash display are replaced at the same time. The hourmeter data is stored in the master controller during every 6 minutes of operation. If there is a loss of power, data is not lost.

STATUS CODE LIST

1. 2. 3. 4.

4 SEGMENTS ADJACENT TO RED 4 SEGMENTS ADJACENT TO ORANGE 12 SEGMENTS ADJACENT TO GREEN BDI SHOWS APPROXIMATELY 65-70% CHARGE Figure 15. Battery Discharge Indication in Dash Display LCD Window

The lift interrupt feature is controlled by the vehicle master controller and prevents the lift function when

16

The status code list is a stored history of selected status codes for malfunctions or incorrect truck use that have occurred since the list was last cleared of entries by a technician. These selected status codes are NOT a list of malfunctions or symptoms that are currently present, but a list of those that have occurred in the past. The list can only be read with the key in the OFF position. To access the status code list, wait until after the traction and pump hours have been displayed, then push the STAR button. All of the status codes in the list will then be shown in sequence. After the last status code, END FAULT CODE HISTORY will be shown.

2200 SRM 1087

Dash Display Service Menu Navigation

Dash Display Service Menu Navigation GENERAL To enter the service mode, turn the key to the ON position and press the (*) button twice. Enter Password prompt will appear on the display. See Figure 16. All lift trucks will have 55555 as the default service password at the time of delivery. This password can be changed by a service technician. Go to Editing and Adding Information.

reached. To return to a previous menu item, press the [1] key. When the last menu item is reached and the [2] key is pressed again, the first menu item will return to the display. 2. To move into a submenu of a main menu item, press the [4] key on the dash display numeric key pad. To move into a sub submenu, as with the Diagnostics Menu, press the [4] key again. 3. To move up or down within the submenu or the sub submenu, press the [1] or [2] keys. 4. To move out of the sub submenu and return to the submenu, press the [3] key. 5. To move out of the submenu and return to the main menu, press the [3] key.

Figure 16. Password Prompt

6. To exit the service mode, press the [3] key.

Buttons [1], [2], [3], [4], and [*] are used for menu navigation and for adding or editing information. Button [5] is only used if it is part of the password required to enter the service mode. The display has arrows on the buttons to aid in the navigation process. See Figure 17.

EDITING AND ADDING INFORMATION NOTE: The setup and password menus can be used to edit or add information to the truck software. When an item in these menus is selected, the current value will be displayed. The characters available to be selected from the display are 0-9, A-Z, blank, and dash. Each line in the display can have no more than 20 characters including blanks. 1. If a change is to be made, press the [4] key and the cursor will blink on one of the characters. Keys [3] and [4] are used to move from character to character in the item being changed.

Figure 17. Dash Display Buttons The following list is the numbers on the dash display and their function: 1. Is up, for scrolling up 2. Is down, for scrolling down 3. Is left, for scrolling left or out of the current menu 4. Is right, for scrolling right or deeper into the next menu level

MOVING THROUGH MENU SELECTIONS 1. When the service technician’s password is correctly entered, the first menu item, which is the hourmeter, is displayed on the dash display LCD screen. To view the next menu item, press the [2] key on the dash display numeric key pad. Repeat this until the desired menu item has been

2. When a character that is to be changed is blinking, use keys [1] and [2] to scroll up or down until the desired character is found. Use keys [3] or [4] to move to the next character to be changed. This is repeated until all changes in the item have been made. 3. When all changes have been made, press the [*] key to store the value. Press the [1] or [2] key to access the next item to be changed. Repeat this procedure for each item that is to be changed. 4. When all changes have been made, press the [3] key to exit the menu.

17

Troubleshooting

2200 SRM 1087

ETACC Test If you have access to the ETACC software, the following tests may be conducted.

MANUAL HYDRAULICS: Connect dongle between the truck and your pc. Turn on the truck, select the proper truck configuration, and click the connect button. Ensure the "connected" icon is showing. • If the red LED on the IFAK dongle is flashing, disconnect the dash display connector. If the LED stops flashing, the dash display may be defective. If the LED continues to flash, go to the next step. • Reconnect the dash display connector and disconnect connector A from the traction controller. If the LED stops flashing, the traction controller may be defective. If the LED continues to flash, the wiring harness may be defective.

ELECTRO-HYDRAULICS: Connect dongle between the truck and your pc. Turn on the truck, select the proper truck configuration, and click the connect button. Ensure the "connected" icon is showing. • If the red LED on the IFAK dongle is flashing, disconnect the 6 pin connector and the joystick. If LED stops flashing, the ILM controller may be defective. If LED continues to flash, go to next step. • Disconnect the dash display connector and connector B at the traction controller. If LED stops flashing, the traction controller may be defective. If LED continues to flash, go to next step. • Reconnect the dash display and connector B. If LED stops flashing, the controller may be defective. If LED continues to flash, the wiring harness may be defective.

Troubleshooting GENERAL The AC motor and master controllers are sealed units with no serviceable components. Troubleshooting is usually limited to accessing status codes and following the diagnostic procedures listed in the Status Code Charts. Use standard testing procedures to verify inputs and outputs when necessary.

CAUTION Never attempt to probe through the back of the connector plugs of the motor controller. These plugs are special sealed plugs. Probing through the back of the plugs will destroy the seal and can cause a short circuit. If a circuit must be tested for voltage, check for voltage at an amp-type plug, a switch, or a component. If a circuit is suspect, check the circuit for continuity by disconnecting the P plug and testing continuity from the front (pin end) of the plug. Standard probes are too large to be inserted into the center of the female pins (sockets) of the special sealed plugs and can expand the

18

pins. Expanded pins will not provide good connections once the plug is reconnected. The connectors are shaped to allow the insertion of a small flat blade screwdriver into the connector. After inserting the screwdriver into the connector attach probes with alligator clips to the shank of the screwdriver to obtain readings. An additional method would be to use a breakout kit Hyster P/N 1397311. See Diagrams 8000 SRM 1081 for additional wiring details. If the lift truck does not operate correctly, a status code is displayed on the display panel. Once the status code number is obtained, follow the procedures outlined in the Status Code Charts of this manual to determine the problem. NOTE: Due to the interaction of the master controller with all lift truck functions, almost any status code or controller fault could be caused by an internal failure of the master controller. After all other status code procedures have been followed and no problem is found, the master controller should be replaced as the last option to correct the problem.

2200 SRM 1087

Troubleshooting

Tools and test equipment required are: clip leads, volt ohmmeter (20,000 ohms per volt), and basic hand tools. Check resistance on RX1000 scale from frame to power and controller terminals. Resistance of less than 20,000 ohms can cause misleading symptoms. Resistance of less than 1000 ohms should be corrected first. Before proceeding, visually check for loose wiring, misaligned linkage to the accelerator switch, signs of overheating of components, etc.

STATUS CODES NOTE: Make sure the parameter values are correct for your lift truck to ensure the trouble is not just an incorrect setting. See Function Parameters to set the correct parameter values. If there is no status code display and the lift truck does not operate correctly, there can be a fault in the master controller.

The status codes are code numbers for malfunctions or lift truck operations that are not correct and that the motor controller can sense. The master controller will indicate this code number on the LCD screen of the display panel. The master and motor controllers sense the following types of malfunctions: • Input voltages that are too high or too low • Input voltages in the wrong sequence or • Correct input voltages that occur at the wrong time NOTE: A status code indication does not always mean that there is a malfunction. A temporary operating condition can cause a status code display. These code numbers are only codes to help identify a possible malfunction. A short description of the different status codes is shown in Table 4. The Status Code Charts in this section have a more complete description of the status code, the circuit that has generated the input for the status code, the symptom, and the possible causes.

Table 4. List of Status Codes Status Code

Description

01

Request traction or hydraulic function while seat switch open.

02

Forward switches closed at key on.

03

Reverse switches closed at key on.

05

Start switch not closed when seat switch is closed and either the forward or reverse directional switch is closed and accelerator voltage shows demand for traction.

06

Request traction function while forward and reverse switches are opened.

07

Accelerator input voltage too high on power up.

08

Accelerator input voltage too low on power up.

09

Forward and reverse direction requested together.

11

Start switch closed before key or seat switch.

12

Steer sensor feedback voltage too low.

13

Steer sensor feedback voltage too high.

14

After steer calibration, controller senses "max right" parameter to be less than "max left" parameter.

15

Battery voltage lower than the setting in controller.

16

Battery voltage higher than the setting in controller.

41

High temperature in master or slave or both power sections, performance is progressively reduced as temperature rises.

19

Troubleshooting

2200 SRM 1087

Table 4. List of Status Codes (Continued) Status Code 42

Pump control temperature too high.

43L

Left traction motor temperature out of range.

43R

Right traction motor temperature out of range.

51

Capacitor voltage too low.

52L

Failure in encoder, in encoder to controller connection, or in controller input circuit, left motor.

52R

Failure in encoder, in encoder to controller connection, or in controller input circuit, right motor.

62

Backup alarm driver shorted. Overcurrent protection activated.

65

Main line contactor coil driver shorted.

66L

Left traction motor shorted.

66R

Right traction motor shorted.

90L

Left traction motor high temperature.

90R

Right traction motor high temperature.

91

Pump motor high temperature.

95

Pump motor brushes worn.

99

Maintenance required.

142

Controller senses no pump current.

143

Controller senses low pump current.

145

Power transistor did not turn on properly.

201

Request hydraulic or traction function while arm rest switch not closed.

202

Hydraulic oil low.

203

Brake fluid low.

204

Request traction or hydraulic function while hood switch/switches not closed.

207

Lift cutout.

208

Pump incorrect start.

209L

Brake coil open, disabling traction.

209R

Brake coil open, disabling traction.

210

20

Description

Internal "watchdog" hardware circuit triggered.

212L

Problem with UVW voltage feedback in slave controller.

212R

Problem with UVW voltage feedback in master controller.

213

The controller has detected an overvoltage or an undervoltage condition within the controller.

214L

Wrong voltage on one phase --> failure in power section (high leg), driver circuit, or motor in slave controller.

2200 SRM 1087

Troubleshooting

Table 4. List of Status Codes (Continued) Status Code

Description

214R

Wrong voltage on one phase --> failure in power section (high leg), driver circuit, or motor in master controller.

215L

Wrong voltage on one phase --> failure in power section (low leg), driver circuit, or motor in slave controller.

215R

Wrong voltage on one phase --> failure in power section (low leg), driver circuit, or motor in master controller.

222

Controller checks to ensure main contactor coil or brake coil is not shorted at start up.

223

Controller checks main contactor tips and ensures they are open before powering controller.

224

Main contactor not closed.

226

Electric brake driver damaged (shorted or open).

227

Traction controller receives a signal for traction from accelerator potentiometer without start switch being closed.

238

Internal failure of traction controller hardware.

239

Master controller detected problem in slave controller functionality.

240

Slave controller detected problem in the master controller functionality.

241

Master does not see CAN messages from slave.

242

Master does not see CAN messages from electro-hydraulic lever console.

243

Slave does not see CAN messages from valve driver module.

244

Failure of dash display memory.

245

Master does not see CAN messages from display.

246

Slave does not see CAN messages from display.

247

Valve driver does not see CAN messages from display.

248

Slave does not see CAN messages from master.

249

No communication from slave to EV.

250L

Left rotor locked.

250R

Right rotor locked.

260

Incorrect voltage on pump motor --> failure in power section, driver section, or motor itself.

270

Error in lift/lower lever.

271

Error in tilt lever.

272

Error in 3rd function lever.

273

Error in 4th function lever.

275

Internal failure of valve driver module.

276

One of the EV drivers of group 1 (lift/lower) is shorted.

277

One of the EV drivers of group 2 (auxiliary in/out) is shorted.

21

Troubleshooting

2200 SRM 1087

Table 4. List of Status Codes (Continued) Status Code

Description

279

One of the EV drivers of group 3 (tilt up/down) is shorted.

280

One of the EV drivers of group 4 (sideshift R/L) is shorted.

281

Driver of single EV (9th) is shorted.

282

One of the on/off EV drivers is shorted.

283

One of the on/off EV coils is shorted; short-circuit protection is triggered.

289

Voltage supply to the valve driver control module is low.

292

IBattery selection is wrong in valve controller.

294

Interlocked hydraulic function requested without activation of interlock switch.

295

Hi-Lift switch is closed and the Lo-Lift switch is open.

299

CAN wires configuration problem.

Status Code

Premium Display Message

Memory Recall

Circuit

01

NO SEAT SWITCH INPUT

No

Traction

Description Controller is not receiving an input signal from the seat switch while receiving a traction or hydraulic function command. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Seat switch malfunction. Check to see if the seat switch operates properly. Use the dash display diagnostics menu to check the seat switch operation. Replace failed switch. • Check continuity of wiring to and from the seat switch to the traction controller. Pin C33 at motor controller to seat switch. Seat switch to Pin C18 at motor controller.

22

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

02

FORWARD SWITCH CLOSED

No

Traction

Description Forward directional switch is closed before the key switch closes. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • A directional switch is engaged before startup. Return directional switch to neutral. • A directional switch is failed, closed, or out of adjustment. Use dash display diagnostics menu to check operation of the directional switches. Replace failed switch. Adjust switch for correct operation. See the section Electrical System 2200 SRM 1078. • Check for a shorted condition between wire #6 and B+. Wire #6 will be at battery voltage when the switch is closed. Wire #6 will be at 0 volts when the switch is open.

23

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

03

REVERSE SWITCH CLOSED

No

Traction

Description Reverse directional switch is closed before the key switch closes. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • A directional switch is engaged before startup. Return directional switch to neutral. • A directional switch is failed, closed, or out of adjustment. Use dash display diagnostics menu to check operation of the directional switches. Replace failed switch. Adjust switch for correct operation. See the section Electrical System 2200 SRM 1078. • Check for a shorted condition between wire #8 and B+. Wire #8 will be at battery voltage when the switch is closed Wire #8 will be at 0 volts when the switch is open.

24

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

05

START SWITCH NOT CLOSED

No

Traction

Description Start switch is open when the seat switch is closed and either the forward or reverse directional switch is closed and the accelerator output voltage shows there is a demand for traction. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Malfunction of the start switch. Use dash display diagnostics to check operation of the start switch. Check for proper switch adjustment. Replace start switch. • Malfunction of the start switch. Check for open circuit or loose connections in wiring from the key switch to the start switch and from the controller to the start switch. Wire #15 will be at battery voltage when the switch is closed. Wire #15 will be at 0 volts when the switch is open.

25

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

06

NO DIRECTION SELECTED

No

Traction

Description The forward and the reverse switches are both open and there is a request for traction. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Accelerator pedal is depressed before closing a directional switch. Status code will disappear when the pedal is released. • Open circuit between the directional switch and the controller. Use dash diagnostics to check the operation of the switch. Check wiring from C4 to FWD and REV switches. Use ohm meter to ensure proper operation of direction switches. Check for continuity between C4 and C6 or C4 and C7 when each switch closes. Check wiring from switches to C6 and C7. Check operation of switch for continuity through the switch when the switch is closed. • Malfunction of the directional switch. Check switch adjustment. FWD or REV switch is closed when direction is selected. • Wire #6 will be at battery voltage when the FWD switch is closed. • Wire #8 will be at battery voltage when the REV switch is closed. • Wires # 6 & #8 will be at 0 volts when the switches are open.

26

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

07

THROTTLE POT ERROR

Yes

Traction

Description Accelerator input voltage is too high when the key is first moved to the ON position. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Accelerator unit has a malfunction or is out of adjustment. Maximum accelerator wiper voltage should be 4.6 volts with the pedal fully up at C33. Check for open circuit between accelerator and controller. Recalibrate throttle. See the section Electrical System 2200 SRM 1078. • Check for 5 volts between wire # 27 and wire # 28 at the throttle potentiometer.

27

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

08

THROTTLE VOLTAGE LOW

No

Traction

Description Accelerator input voltage is lower than threshold voltage set at throttle calibration. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Accelerator unit has a malfunction or is out of adjustment. Check for open circuit between accelerator and controller. Minimum accelerator wiper voltage should be 0.5 volt with the pedal fully down at C21. Recalibrate throttle. See the section Electrical System 2200 SRM 1078. • Check for 5 volts between wire # 27 and wire # 28 at the throttle potentiometer.

28

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

09

FWD and REV SWITCHES CLOSED AT SAME TIME

No

Traction

Description Both the forward and reverse directional switches are closed at the same time. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Either the forward or reverse switch is failed closed. Use dash display diagnostic to check operation of directional switches. Replace failed or malfunctioning switch. • Directional switch is out of adjustment. Switches should be open with directional switch in neutral. • Wire #6 will be at battery voltage when the FWD switch is closed. • Wire #8 will be at battery voltage when the REV switch is closed. • Wires # 6 & #8 will be at 0 volts when the switches are open.

29

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

11

START SWITCH CLOSED BEFORE KEY

No

Traction

Description Accelerator start switch is closed before the key and/or the seat switch. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Accelerator pedal depressed when key is turned to ON position. Release pedal and restart. • Accelerator start switch is out of adjustment. Switch should be open with accelerator pedal fully up. • Accelerator start switch is shorted closed. Use dash display diagnostic menu to check operation of switch. Replace failed switch. • Wire # 15 will be at battery voltage when the start switch is closed. • Wire # 15 will be at 0 volts when the start switch is open.

30

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

12

STEER SENSOR VOLTAGE LOW

Yes

Traction

Description Steer sensor feedback voltage is too low. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Use dash diagnostics to check operation of the steer sensor. • Check potentiometer and adjustment. Potentiometer wiper should be set at 5K ohms with wheels straight ahead. • Check wiring continuity between steering potentiometer and traction controller. • Check voltage between C15 and C16. Voltage should be 5.0 volts. • Check for 5.0 volts between wire # 70 and Wire # 72 at the steer potentiometer. • Recalibrate steering. See the section Electrical System 2200 SRM 1078. Check voltage at C17 at the traction controller. Voltage is typically 2.2 volts with the steer wheel in the straight ahead position. • Operate the lift truck and recheck the steering potentiometer voltage to ensure the system will mechanically remain in calibration.

31

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

13

STEER SENSOR VOLTAGE HIGH

Yes

Traction

Description Steer sensor feedback voltage is too high. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Use dash diagnostics to check operation of the steer sensor. • Check potentiometer and adjustment. Potentiometer wiper should be set at 5K ohms with wheels straight ahead. • Check wiring continuity between steering potentiometer and traction controller. • Check voltage between C15 and C16. Voltage should be 5.0 volts. • With steer wheel straight ahead, check for 2.2 volts at C17 on the traction controller. • Recalibrate steering. See the section Electrical System 2200 SRM 1078.

32

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

14

WRONG STEER CALIBRATION

Yes

Traction

Description After steer calibration, the controller is sensing the "max right" parameter to be less than the "max left" parameter. Symptom No lift truck operation. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Recalibrate the steering sensor. • Check sensor values using the dash diagnostics. • Check adjustment of the steering potentiometer. • Check for 5.0 volts between wire # 70 and Wire # 72 at the steer potentiometer. • Check voltage at C17 at the traction controller. Voltage is typically 2.2 volts with the steer wheel in the straight ahead position. • Operate the lift truck and recheck the steering potentiometer voltage to ensure the system will mechanically remain in calibration.

33

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

15

BATTERY VOLTAGE LOW

Yes

Traction

Description The battery voltage is lower than the setting in the controller.

Symptom Lift truck does not move. Probable Causes and Test Procedures • Incorrect battery installed in truck. • Ensure all fuses are properly seated and tight in the fuse holders. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Discharged battery. Check battery for correct open circuit voltage. Charge battery. • Battery is damaged. Check each cell for correct voltage (greater than 1.85 volts per cell). Repair or replace battery. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Incorrect controller adjustment. Use dash display to check battery voltage. • Check condition of main contactor tips.

34

NOMINAL BATTERY VOLTAGE

MINIMUM LIMIT VOLTS AT 1.85 VDC PER CELL

36

33.3

48

44.4

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

16

BATTERY VOLTAGE HIGH

Yes

Traction

Description The battery voltage is higher than the setting in the controller.

Symptom Lift truck does not move.

NOMINAL BATTERY VOLTAGE

MAXIMUM LIMIT VOLTS AT 2.40 VDC PER CELL

36

43.2

48

57.6

Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Incorrect battery installed in truck. • Overcharged battery. Check battery for correct open circuit voltage. • Incorrect controller adjustment. Use dash display to check battery voltage. • Check condition of main contactor tips.

35

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

41

TRACTION CONTROL TEMPERATURE HIGH

Yes

Traction

Description High temperature in the traction controller power section. Truck performance is progressively reduced as temperature rises. Symptom Traction performance is reduced. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Reduce duty cycle until temperature is reduced. • If fault is indicated when controller is cold, replace controller. • Check for dragging parking brakes or service brakes. • Use dash diagnostics to check for correct current level of the left and right traction motors and the pump motor. • Check for mechanical offset of steering potentiometer. Recalibrate as necessary.

36

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

42

PUMP CONTROL TEMPERATURE HIGH

Yes

Hydraulic

Description Pump controller temperature is too high. Traction performance is progressively reduced as temperature increases. Symptom Traction performance is reduced. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Reduce duty cycle until temperature is reduced. • If fault is indicated when controller is cold, replace controller. • Check for dragging parking brakes or service brakes. • Use dash diagnostics to check for correct current level of the left and right traction motors and the pump motor. • Check for mechanical offset of steering potentiometer. Recalibrate as necessary.

37

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

43L

LEFT MOTOR TEMP OUT OF RANGE

Yes

Traction

Description Left traction motor temperature is out of range. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Failed thermal sensor in traction motor. Using dash display diagnostic, check motor temperature. • Check the motor temperature sensor resistance at the traction controller between C34 and C35. Resistance should read 500 ohms at24 C (75 F). • Check for a shorted condition between C34 and the truck frame and C35 and the truck frame. Should see a minimum 1 megohm resistance.

38

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

43R

RIGHT MOTOR TEMP OUT OF RANGE

Yes

Traction

Description Right traction motor temperature is out of range. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Failed thermal sensor in traction motor. Using dash display diagnostic, check motor temperature. • Check the motor temperature sensor resistance at the traction controller between C24 and C25. Resistance should read 500 ohms at24 C (75 F). • Check for a shorted condition between C24 and the truck frame and C25 and the truck frame. Should see a minimum 1 megaohm resistance.

39

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

51

PRECHARGE

Yes

Traction

Description Controller capacitor voltage does not increase at startup. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Ensure the towing connector near the dash display is not in place. • Remove fuse FU3 and turn the key to the ON position. If the problem remains, perform Test A. If the problem does not reappear, perform Tests B. Test A: Disconnect the battery and discharge the capacitors. See Discharging Capacitors in the front of this section. Disconnect the B+ cable from the traction controller. Connect and ohm meter between the B+ and the B- terminals of the traction controller. Look for an increasing resistance from 0 to 150 ohms over 10 seconds. Disconnect the ohm meter and discharge the capacitors. See Discharging Capacitors in the front of this section. Connect the ohm meter negative lead to Band ohm meter positive lead to UM. The ohm meter should read approximately 5K ohms. Connect the ohm meter negative lead to Band the ohm meter positive lead to US. The ohm meter should read approximately 5K ohms. Connect the ohm meter negative lead to UM and the ohm meter positive lead to B+. The ohm meter should read approximately 5K ohms. (Continued on next page)

40

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

51 (Cont)

PRECHARGE

Yes

Traction

Description Controller capacitor voltage does not increase at startup. Symptom Lift truck does not move. Probable Causes and Test Procedures • Remove fuse FU3 and turn the key to the ON position. If the problem remains, perform Test A. If the problem does not reappear, perform Tests B (Continued). Test A: (Continued) Connect the ohm meter negative lead to US and the ohm meter positive lead to B+. The ohm meter should read approximately 5K ohms. If any of these tests is failed, replace the controller. Tests B: Check resistance between B+ and B- at the steering motor. The reading should be several thousand ohms. Check for a failed R1 resistor in the steering circuit. Install fuse (FU3), disconnect the dash connector, and turn the key to the ON position. Measure the voltage across B+ and B on the traction controller. If the value is battery voltage, the dash display may be defective. Check for brake driver continuous on. With the key switch in the ON position and the seat switch in the open condition, check that voltage between C28 and C29 in less than 2 volts. Check for welded pump contactor tips. • Wire #47 should be greater than 5 volts after the seat switch opens for more than 10 seconds. • Check the connections of wires #10-6 and #47.

41

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

52L

LEFT ENCODER ERROR

Yes

Traction

Description Incorrect feedback from traction motor speed sensor. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Use dash diagnostics to check encoder operation. • Check for 12-volt supply to encoder. • Ensure wiring to the encoder is correct. See the section Diagrams 8000 SRM 1081. • Ensure all wiring connections between the encoder and the traction motor are tight. • Check continuity of the wiring from the controller to the encoder. • Check for any shorted condition between C1, C2, C13, or C14 to the truck frame. • Disconnect the 6 pin connector from the traction motor and check for pin to pin resistance in the connector on the motor side. There should be a minimum 1 megohm resistance from pin to pin.

42

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

52R

RIGHT ENCODER ERROR

Yes

Traction

Description Incorrect feedback from traction motor speed sensor. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Use dash diagnostics to check encoder operation. • Check for 12-volt supply to encoder. • Ensure wiring to the encoder is correct. See the section Diagrams 8000 SRM 1081. • Ensure all wiring connections between the encoder and the traction motor are tight. • Check continuity of the wiring from the controller to the encoder. • Check for any shorted condition between C1, C2, C13, or C14 to the truck frame. • Disconnect the 6 pin connector from the traction motor and check for pin to pin resistance in the connector of the motor side. There should be a minimum 1 megohm resistance from pin to pin.

43

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

62

REVERSE SIGNAL OUTPUT SHORTED

Yes

Auxiliary

Description Backup alarm driver is shorted. Overcurrent protection has been activated. Symptom Backup alarm does not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Disconnect the dash display A connector and check for shorted wiring between pin A20 and B- or B+. • Check wiring for shorts. • Check for a shorted alarm. • Check the resistance of R3, R4, D1 and LRC1 for proper values if equipped with a DC/DC converter. • Replace dash display.

44

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

65

MAIN CONTACTOR SHORTED

Yes

Traction

Description The main contactor coil driver is shortened. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Disconnect C connector from the traction controller and check the controller for a shorted condition between C26 and B-. • Check the harness for a shorted condition between pin C26 and B+ or B-. • Check for shorted driver at the controller. Check for short between terminal C26 and B . • Check for shorted main contactor coil. Coil should measure approximately 32 ohms.

45

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

66L

LEFT TRACTION MOTOR SHORTED

Yes

Traction

Description Left traction motor is shorted. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Ensure all motor connections are tight. • Ensure motor connections are not shorted to the truck frame. • Disconnect all motor leads from the traction motor. Check line-to-line stator resistance. Resistance should be 10.00 ±0.10 milliohms for 48-volt truck and 6.10 ±0.10 milliohms for 36-volt truck.

46

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

66R

RIGHT TRACTION MOTOR SHORTED

Yes

Traction

Description Right traction motor is shorted. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Ensure all motor connections are tight. • Ensure motor connections are not shorted to the truck frame. • Disconnect all motor leads from the traction motor. Check line-to-line stator resistance. Resistance should be 10.00 ±0.10 milliohms for 48-volt truck and 6.10 ±0.10 milliohms for 36-volt truck.

47

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

90L

LEFT TRACTION MOTOR TEMP HIGH

Yes

Traction

Description Left traction motor high temperature. Temperature sensor in traction motor has indicated high temperature. Symptom Traction performance is reduced. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Use dash display diagnostics to verify motor temperature sensor is operating properly. • Reduce truck operation until motor cools. • If a fault is signaled with cold motor, disconnect the C connector from the traction controller and check the motor temperature sensor resistance between pin C34 and C35 in the connector. The resistance should be 555 ohms to 607 ohms at 20 C (68 F). If the resistance is out of range, disconnect the 6 pin connector at the left traction motor and measure the resistance again between pins 3 and 4 at the motor side of the connector. If the resistance is within range, check the wiring harness. • Check for broken or loose wires. • Disconnect all motor leads from the traction motor and check line to line stator resistance. The resistance should read 10.00 +/-0.10 milliohms for a 48 volt truck and 6/10 +/-0.10 milliohms for a 36 volt truck. If the above readings are within in the specified ranges, compare motor current between the two traction motors using dash display diagnostics. Drive the truck straight ahead and observe the current level of each traction motor. If the left traction motor is drawing significantly more current than the right traction motor check for a dragging service or parking brake. (Continued on next page)

48

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

90L (Cont)

LEFT TRACTION MOTOR TEMP HIGH

Yes

Traction

Description Left traction motor high temperature. Temperature sensor in traction motor has indicated high temperature. Symptom Traction performance is reduced. Probable Causes and Test Procedures • Check for mechanical offset of steering potentiometer. Recalibrate as necessary.

49

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

90R

RIGHT TRACTION MOTOR TEMP HIGH

Yes

Traction

Description Right traction motor high temperature. Temperature sensor in traction motor has indicated high motor temperature. Symptom Traction performance is reduced. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Use dash display diagnostics to verify motor temperature sensor is operating properly. • Reduce truck operation until motor cools. • If a fault is signaled with cold motor, disconnect the C connector from the traction controller and check the motor temperature sensor resistance between pin C34 and C35 in the connector. The resistance should be 555 ohms to 607 ohms at 20 C (68 F). If the resistance is out of range, disconnect the 6 pin connector at the left traction motor and measure the resistance again between pins 3 and 4 at the motor side of the connector. If the resistance is within range, check the wiring harness. • Check for broken or loose wires. • Disconnect all motor leads from the traction motor and check line to line stator resistance. The resistance should read 10.00 +/-0.10 milliohms for a 48 volt truck and 6/10 +/-0.10 milliohms for a 36 volt truck. If the above readings are within in the specified ranges, compare motor current between the two traction motors using dash display diagnostics. Drive the truck straight ahead and observe the current level of each traction motor. If the right traction motor is drawing significantly more current than the right traction motor, check for a dragging service or parking brake. (Continued on next page)

50

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

90R (Cont)

RIGHT TRACTION MOTOR TEMP HIGH

Yes

Traction

Description Right traction motor high temperature. Temperature sensor in traction motor has indicated high motor temperature. Symptom Traction performance is reduced. Probable Causes and Test Procedures • Check for mechanical offset of steering potentiometer. Recalibrate as necessary.

51

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

91

PUMP MOTOR TEMPERATURE HIGH

No

Lift

Description Pump motor temperature too high. Thermal switch in pump motor has been activated. Symptom Display message. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Use dash display diagnostics to verify motor over-temperature switch is activated. • Reduce truck operation until motor cools. • If fault is signaled with a cold motor, disconnect the dash display connector and measure the resistance between A2 and A6 at the harness side of the connector. The resistance should be less than 10 ohms. If the resistance is greater than 10 ohms, disconnect the 4 pin connector at the pump motor and measure the resistance between wires 110 and 102 on the motor side of the connector. If the resistance is less than 10 ohms, check the wiring harness and connectors. • Remove all motor leads from the pump motor and check line to line stator resistance. • Use the dash display to check for high current draw during hydraulic operations if equipped.

52

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

95

PUMP MOTOR BRUSHES

No

Lift

Description Pump motor brushes worn. Brush wear indicator switch in pump motor has been activated. Symptom Dash display message. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Replace pump motor brushes. • Check wiring and connections.

Status Code

Premium Display Message

Memory Recall

Circuit

99

MAINTENANCE REQUIRED

No

None

Description Truck maintenance required. Symptom Dash display message. Flashing "wrench" icon. Probable Causes and Test Procedures • Truck requires scheduled maintenance. • Perform required maintenance activity.

53

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

142

PUMP CURRENT SENSOR MISSING

Yes

Hydraulic

Description Controller senses no pump current. Symptom No hydraulic function. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check that traction motor windings are not shorted to the truck frame. • Check the P+ and P connections at both the controller and the pump motor. • Check for shorts from P+ and P to the truck frame. • Check to see if the pump motor reverses direction when a hydraulic function is returned to neutral. If reverse rotation is observed, check the hydraulic valves for proper operation.

54

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

143

PUMP CURRENT SENSOR LOW

Yes

Hydraulic

Description Controller senses low pump current. Symptom No hydraulic function. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check that traction motor windings are not shorted to the truck frame. • Check the P+ and P connections at both the controller and the pump motor. • Check for shorts from P+ and P to the truck frame. • Check to see if the pump motor reverses direction when a hydraulic function is returned to neutral. If reverse rotation is observed, check the hydraulic valves for proper operation.

55

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

145

PUMP M- FAULT

Yes

Hydraulic

Description Power transistor did not turn on properly. Symptom No lift operation. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check wiring connections between the controller and the pump motor. • Check for open motor windings. • Check for worn pump motor brushes. • Check for any shorted condition between P+ or P- at the pump controller and the truck frame.

56

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

201

NO ARM REST SWITCH INPUT

No

Lift

Description Arm rest switch not closed when requesting traction or hoist functions. Symptom Lift does not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Ensure arm rest is in full down position. Arm rest should be in the locked position. • Use dash diagnostics to check operation of switch. Check all wiring connections to switch. Check switch adjustment. See the section Electrical System 2200 SRM 1078 for adjustment procedure.

57

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

202

HYDRAULIC OIL LOW

No

Lift

Description Hydraulic fluid is low. Symptom Dash display message. Flashing icon on display. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Ensure forks are fully lowered, turn key to the ON position. • Check hydraulic fluid level. Add fluid. See the section Periodic Maintenance 8000 SRM 1079 for correct fluid. • Check sensor for open condition. Ensure all wiring connections are secure. • Check for battery voltage at A9 on the dash display when the hydraulic oil level is full. • Disconnect the dash display connector and measure the resistance between A2 and A9 at the harness side of the connector. The resistance should be less than 10 ohms when the hydraulic oil level is full. If the resistance is greater than 10 ohms, disconnect the 2 pin connector at the hydraulic oil level sensor and measure the resistance at the sensor. If this resistance is less than 10 ohms, check the condition of the wiring harness.

58

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

203

BRAKE FLUID LOW

No

Brake

Description Brake fluid is low. Symptom Dash display message. Flashing icon on display. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check brake master cylinder fluid level. Fill as needed. • Check for loose or broken wires.

CAUTION Do not use DOT brake fluid! This truck uses hydraulic oil in the brake system. See the section Capacities and Specifications 8000 SRM 1080. • Check sensor. Disconnect wiring connector. Remove fill cap and sensor from reservoir. Check resistance across the sensor pins. Resistance is approximately 470 ohms when float is fully raised. Resistance is less than 10 ohms when the float is fully lowered and the switch is closed.

59

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

204

NO HOOD SWITCHES INPUT

No

Traction/Lift

Description Hood switch or switches are open when requesting traction or hydraulic functions. Symptom No traction or lift operation. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check wiring continuity between switches. There are two switches wired in series. Check for battery voltage at C5 with both switches closed. Check each switch for open condition while operating the switch. • Replace failed switch.

60

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

207

LIFT INTERRUPT

No

Lift

Description Fault is set when battery is discharged below 20 percent of full charge. Symptom Lift does not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Occurs when battery is 80 percent discharged. • Discharged battery. Charge or change battery.

61

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

208

PUMP REQUEST BEFORE KEY

No

Lift

Description Incorrect pump motor starting sequence. Symptom Lift does not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. Manual Valve • Recycle key. • Check for a closed hydraulic function switch at the manual hydraulic control valve. Check switch adjustment. Switches should be open with the hydraulic function levers in the neutral position. • Replace failed switch. NOTE: Lift trucks with transistor hydraulics share circuitry between the hydraulic and traction circuits inside the motor controller. This fault code may sometimes be caused by a problem registered from the traction motor encoders. If the lift truck is equipped with transistor hydraulics, perform the following tests: • Disconnect connector “D” from the traction controller. • Check the status of each function’s switches using the dash display. • If the status reading flashes “1” and “0” alternately or if the pump motor runs: Turn the key switch to the OFF position. Disconnect the six pin connectors securing both the left and right traction motor encoders to the main wiring harness. Turn the key switch to the ON position. (Continued on next page)

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Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

208 (Cont)

PUMP REQUEST BEFORE KEY

No

Lift

Description Incorrect pump motor starting sequence. Symptom Lift does not operate. Probable Causes and Test Procedures • If the status reading has stopped flashing “1” and “0” alternately and if the pump motor has stopped: One or both of the encoders is faulty. Check both encoders by measuring the resistance between any combination of connector pins 1, 2, 5, and 6 on the motor side. The resistance should be at least 1 megohm. Parking brakes that are dragging can damage the encoders. Inspect the parking brakes for proper operation when encoders have to be replaced. See Brake System 1800 SRM 1076. Electro-Hydraulic Valve • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Cycle key switch from OFF to ON. • Check for function lever not in neutral. See the section Electro-Hydraulic Control Valve 2000 SRM 1086. • Use the dash display diagnostic to view all hydraulic functions while all levers are in neutral. All functions should show 0%.

63

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

209L

BRAKE COIL OPEN

No

Brake

Description Brake coil is open, disabling traction. Symptom No truck movement, or truck may pull to one side when starting to accelerate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the resistance of the brake coil. The coil resistance should read approximately 32 ohms at 24 C (75 F). • Recycle key switch. • Check for voltage at the brake coil. Should read approximately 36 volts. If no voltage, check wiring for loose connections at the dash display connector pins A12 & A13. Also check pins C28 & C29 at the traction controller. Check for open circuits in the wiring harness. • Check brake circuit diodes. • Check brake circuit diodes D2 and D3 for an open or shorted condition.

64

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

209R

BRAKE COIL OPEN

No

Brake

Description Brake coil is open, disabling traction. Symptom No truck movement, or truck may pull to one side when starting to accelerate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the resistance of the brake coil. The coil resistance should read approximately 32 ohms at 24 C (75 F). • Recycle key switch. • Check for voltage at the brake coil. Should read approximately 36 volts. If no voltage, check wiring for loose connections at the dash display connector pins A12 & A13. Also check pins C28 & C29 at the traction controller. Check for open circuits in the wiring harness. • Check brake circuit diodes. • Check brake circuit diodes D2 and D3 for an open or shorted condition.

65

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

210

WATCHDOG IN TRACTION CONTROLLER

Yes

Traction

Description The internal "watchdog" hardware circuit has been triggered. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Cycle key switch from OFF to ON. • Check resistance between CANL and CANH wires at the controller. Resistance should be approximately 60 ohms. • Ensure CANL, CANH, B+, or B- is not shorted to the frame of the truck. • Ensure CANL or CANH is not shorted to B-. • Ensure CANL and CANH is not shorted to B+. • If the truck is equipped with electro-hydraulics option, check for continuity between the hydraulic levers mounting plate and the truck frame. • ETACC tests may be conducted on the system if you have access to the ETACC software. Refer to ETACC Test.

66

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

212L

LEFT U.V.W. VOLTAGE FEEDBACK

Yes

Traction

Description Problem with UVW voltage feedback in slave controller. Symptom No traction. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check that traction motor windings are not shorted to the truck frame.

Status Code

Premium Display Message

Memory Recall

Circuit

212R

RIGHT U.V.W. VOLTAGE FEEDBACK

Yes

Traction

Description Problem with UVW voltage feedback in master controller. Symptom No traction. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check that traction motor windings are not shorted to the truck frame.

67

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

213

UNDER/OVER VOLTAGE

Yes

Internal Controller

Description The controller has detected an overvoltage or an undervoltage condition within the controller. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Cycle key switch from OFF to ON. • Check that the battery is the proper voltage and is fully charged. Check the specific gravity of each cell. • If a fault occurs at key ON, disconnect the dc-dc converter if installed on the truck. • If the fault occurs when a hydraulic or traction function is activated, check the battery disconnect switch condition and the main contactor tip condition.

68

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

214L

LEFT MOTOR VOLTAGE LOW

Yes

Traction

Description Incorrect voltage on one phase of the power circuit. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check all wiring connections to motors and controller. All connections should be tight. • Ensure power wires are connected to correct terminals. See the section Diagrams 8000 SRM 1081. • Check the resistance of each motor winding. Each winding should measure approximately 10.00 ±0.10 milliohms (48V) and 6.10 ±0.10 milliohms (36V). • Ensure each of the motor windings is not shorted to the truck frame.

69

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

214R

RIGHT MOTOR VOLTAGE LOW

Yes

Traction

Description Incorrect voltage on one phase of the power circuit. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check all wiring connections to motors and controller. All connections should be tight. • Ensure power wires are connected to correct terminals. See the section Diagrams 8000 SRM 1081. • Check the resistance of each motor winding. Each winding should measure approximately 10.00 ±0.10 milliohms (48V) and 6.10 ±0.10 milliohms (36V). • Ensure each of the motor windings is not shorted to the truck frame.

70

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

215L

LEFT MOTOR VOLTAGE HIGH

Yes

Traction

Description Incorrect voltage on one phase of the power circuit. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check all wiring connections to motors and controller. All connections should be tight and clean. • Ensure power wires are connected to correct terminals. See the section Diagrams 8000 SRM 1081. • Check the resistance of each motor winding. Each winding should measure approximately 10.00 ±0.10 milliohms (48V) and 6.10 ±0.10 milliohms (36V). • Ensure each of the motor windings is not shorted to the truck frame.

71

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

215R

RIGHT MOTOR VOLTAGE HIGH

Yes

Traction

Description Incorrect voltage on one phase of the power circuit. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check all wiring connections to motors and controller. All connections should be tight and clean. • Ensure power wires are connected to correct terminals. See the section Diagrams 8000 SRM 1081. • Check the resistance of each motor winding. Each winding should measure approximately 10.00 ±0.10 milliohms (48V) and 6.10 ±0.10 milliohms (36V). • Ensure each of the motor windings is not shorted to the truck frame.

72

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

222

MAIN OR BRAKE COIL OVERCURRENT

Yes

Traction

Description The controller checks to ensure the main contactor or brake coils are not shorted at start up. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check for shorted main contactor coil. Coil should measure approximately 32 ohms resistance across the coil terminals. • Check for shorted wiring. • Check for shorted brake coils. Coil should measure 32.5 ohms resistance across the coil leads. • Check for shorted condition between pins C26 & C27 and between pins C28 & C29 at the traction controller.

73

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

223

MAIN CONTACTOR WELDED

Yes

Traction

Description The controller checks the main contactor tips and ensures they are open before powering the controller. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check that the main contactor tips are not welded. • Open contactor tips and replace if needed.

74

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

224

MAIN CONTACTOR NOT CLOSED

Yes

Traction

Description The controller checks to ensure the main contactor closes after power has been supplied to the contactor coil. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Ensure contactor is not stuck in open position. • Check the contactor coil. Coil should measure approximately 32 ohms resistance. • Check wiring from the controller to the contactor coil. Check for continuity from C26 to coil. Check for continuity from C27 to coil. • Check for shorted condition between C26 and the truck frame. • Check for shorted condition between C27 and the truck frame.

75

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

226

BRAKE DRIVER OPEN OR SHORTED

Yes

Traction

Description Internal check of the parking brake driver in the controller. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check for a shorted condition between C28 at harness side of the connector and B-. If there is an indication of low resistance while making this check, check the wire harness for shorts. • Check for a shorted condition between C28 and B- at the controller side. If there is an indication of low resistance while making this check, the controller may be defective. • Check the brake coil resistance, the brake coil should measure approximately 31 ohms. • Check for a shorted condition between pin C28 at the traction controller and the truck frame. Check for a shorted condition from pin C29 to the truck frame at the traction controller.

76

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

227

THROTTLE VOLTAGE HIGH

No

Traction

Description The traction controller is receiving a signal for traction from the accelerator potentiometer without the start switch being closed. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Accelerator potentiometer is out of adjustment. Recalibrate throttle. See the section Electrical System 2200 SRM 1078. • Malfunction of the start switch. Use dash display diagnostics to check operation of the start switch. Check for proper switch adjustment. • Use the dash display diagnostics to check operation of the throttle sensor. Replace throttle sensor if necessary. • Check for a shorted condition between pins C20, C21 and C33 at the traction controller and the truck frame.

77

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

238

TRACTION CONTROLLER FAULT

Yes/No

Traction

Description Internal failure of the traction controller hardware. Symptom Lift truck will not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the condition of the main contactor and pump contactor (if equipped) tips. • Recycle key from OFF to ON. • If the truck is equipped with a pump controller, check all pump motor power connections and cables. Check for a shorted condition between P+ and the truck frame and between P- and the truck frame. Check for reverse rotation of the pump motor when returning a hydraulic function to neutral. If reverse rotation is observed, check hydraulic valves for proper operation.

78

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

239

ALARM IN SLAVE

Yes

Internal Controller

Description Master controller has detected a problem with the slave controller. Symptom Lift truck does not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the condition of the main contactor and pump contactor (if equipped) tips. • Recycle key from OFF to ON. • Check resistance between CANH and CANL wires at the traction controller. Resistance should be approximately 60 ohms. • Check CANL, CANH, B+, and B- are not shorted to the frame of the truck. • Check CANL and CANH are not shorted to B- or B+. • Check all CANbus wiring for loose connections or damaged wiring. • If the truck is equipped with electro-hydraulics option, check for continuity between the hydraulic levers mounting plate and the truck frame. • ETACC tests may be conducted on the system if you have access to the ETACC software. Refer to ETACC Test.

79

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

240

ALARM IN MASTER

Yes

Internal Controller

Description Slave controller has detected a problem with the master controller. Symptom Lift truck does not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the condition of the main contactor and pump contactor (if equipped) tips. • Recycle key from OFF to ON. • Check resistance between CANH and CANL wires at the traction controller. Resistance should be approximately 60 ohms. • Check CANL, CANH, B+, and B- are not shorted to the frame of the truck. • Check CANL and CANH are not shorted to B- or B+. • Check all CANbus wiring for loose connections or damaged wiring. • If the truck is equipped with electro-hydraulics option, check for continuity between the hydraulic levers mounting plate and the truck frame. • ETACC tests may be conducted on the system if you have access to the ETACC software. Refer to ETACC Test.

80

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

241

NO COMMUNICATION SLAVE TO MASTER

Yes

Internal Controller

Description Master controller is not receiving CAN messages from the slave controller. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the condition of the main contactor and pump contactor (if equipped) tips. • Recycle key from OFF to ON. • Check resistance between CANH and CANL wires at the traction controller. Resistance should be approximately 60 ohms. • Check CANL, CANH, B+, and B- are not shorted to the frame of the truck. • Check CANL and CANH are not shorted to B- or B+. • Check all CANbus wiring for loose connections or damaged wiring. • If the truck is equipped with electro-hydraulics option, check for continuity between the hydraulic levers mounting plate and the truck frame. • ETACC tests may be conducted on the system if you have access to the ETACC software. Refer to ETACC Test.

81

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

242

NO COMMUNICATION LEVER TO MASTER

Yes

Lift

Description Master controller is not receiving CAN messages from the electro-hydraulic lever console. Symptom Lift does not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the condition of the main contactor and pump contactor (if equipped) tips. • Recycle key from OFF to ON. • Check resistance between CANH and CANL wires at the traction controller. Resistance should be approximately 60 ohms. • Check CANL, CANH, B+, and B- are not shorted to the frame of the truck. • Check CANL and CANH are not shorted to B- or B+. • Check all CANbus wiring for loose connections or damaged wiring. • If the truck is equipped with electro-hydraulics option, check for continuity between the hydraulic levers mounting plate and the truck frame. • ETACC tests may be conducted on the system if you have access to the ETACC software. Refer to ETACC Test.

82

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

243

NO COMMUNICATION EV TO SLAVE

Yes

Lift

Description Slave controller is not receiving CAN messages from the electro-hydraulic valve driver module. Symptom Lift does not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the condition of the main contactor and pump contactor (if equipped) tips. • Recycle key from OFF to ON. • Check resistance between CANH and CANL wires at the traction controller. Resistance should be approximately 60 ohms. • Check CANL, CANH, B+, and B- are not shorted to the frame of the truck. • Check CANL and CANH are not shorted to B- or B+. • Check all CANbus wiring for loose connections or damaged wiring. • If the truck is equipped with electro-hydraulics option, check for continuity between the hydraulic levers mounting plate and the truck frame. • ETACC tests may be conducted on the system if you have access to the ETACC software. Refer to ETACC Test.

EV = Electro-hydraulic valve driver module.

83

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

244

DASH DISPLAY FAULT

No

Display

Description Failure of the dash display memory. Symptom Dash display does not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Recycle key from OFF to ON. • Check all wiring and pins in the dash display connector are tight and secure.

84

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

245

NO COMMUNICATION MASTER TO DASH

Yes

Traction

Description Master controller is not receiving CAN messages from the dash display. Symptom Lift truck does not move or moves very slowly. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the condition of the main contactor and pump contactor (if equipped) tips. • Recycle key from OFF to ON. • Check termination resistor. Should measure approximately 60 ohms between A7 and A22 at the dash display. • Check resistance between CANH and CANL wires at the traction controller. Resistance should be approximately 60 ohms. • Check CANL, CANH, B+, and B- are not shorted to the frame of the truck. • Check CANL and CANH are not shorted to B- or B+. • Check all CANbus wiring for loose connections or damaged wiring. • If the truck is equipped with electro-hydraulics option, check for continuity between the hydraulic levers mounting plate and the truck frame. • ETACC tests may be conducted on the system if you have access to the ETACC software. Refer to ETACC Test.

85

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

246

NO COMMUNICATION SLAVE TO DASH

Yes

Traction

Description Slave controller is not receiving CAN messages from dash display. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the condition of the main contactor and pump contactor (if equipped) tips. • Recycle key from OFF to ON. • Check termination resistor. Should measure approximately 60 ohms between A7 and A22 at the dash display. • Check resistance between CANH and CANL wires at the traction controller. Resistance should be approximately 60 ohms. • Check CANL, CANH, B+, and B- are not shorted to the frame of the truck. • Check CANL and CANH are not shorted to B- or B+. • Check all CANbus wiring for loose connections or damaged wiring. • If the truck is equipped with electro-hydraulics option, check for continuity between the hydraulic levers mounting plate and the truck frame. • ETACC tests may be conducted on the system if you have access to the ETACC software. Refer to ETACC Test.

86

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

247

NO COMMUNICATION EV TO DASH

Yes

Lift

Description Electro-hydraulic valve driver module is not receiving CAN messages from the dash display. Symptom Lift does not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the condition of the main contactor and pump contactor (if equipped) tips. • Recycle key from OFF to ON. • Check continuity of the CANbus wires between the dash display and the valve driver module. • Check resistance between CANH and CANL wires at the traction controller. Resistance should be approximately 60 ohms. • Check CANL, CANH, B+, and B- are not shorted to the frame of the truck. • Check CANL and CANH are not shorted to B- or B+. • Check all CANbus wiring for loose connections or damaged wiring. • If the truck is equipped with electro-hydraulics option, check for continuity between the hydraulic levers mounting plate and the truck frame. • ETACC tests may be conducted on the system if you have access to the ETACC software. Refer to ETACC Test.

EV = Electro-hydraulic valve driver module.

87

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

248

NO COMMUNICATION MASTER TO SLAVE

Yes

Internal Controller

Description Slave controller is not receiving CAN messages from the master controller. Symptom Lift truck does not move. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the condition of the main contactor and pump contactor (if equipped) tips. • Recycle key from OFF to ON. • Check continuity of the CANbus wires between the dash display and the valve driver module. • Check resistance between CANH and CANL wires at the traction controller. Resistance should be approximately 60 ohms. • Check CANL, CANH, B+, and B- are not shorted to the frame of the truck. • Check CANL and CANH are not shorted to B- or B+. • If the truck is equipped with electro-hydraulics option, check for continuity between the hydraulic levers mounting plate and the truck frame. • ETACC tests may be conducted on the system if you have access to the ETACC software. Refer to ETACC Test.

88

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

249

NO COMMUNICATION SLAVE TO EV

Yes

Internal Controller

Description EV controller is not receiving CAN messages from the slave controller. Symptom Truck will not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check the condition of the main contactor and pump contactor (if equipped) tips. • Recycle key from OFF to ON. • Check resistance between CANH and CANL wires at the traction controller. Resistance should be approximately 60 ohms. • Check CANL, CANH, B+, and B- are not shorted to the frame of the truck. • Check CANL and CANH are not shorted to B- or B+. • Check all CANbus wiring for loose connections or damaged wiring. • If the truck is equipped with electro-hydraulics option, check for continuity between the hydraulic levers mounting plate and the truck frame. • ETACC tests may be conducted on the system if you have access to the ETACC software. Refer to ETACC Test.

EV = Electro-hydraulic valve driver module.

89

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

250L

LEFT ROTOR LOCKED

Yes

Traction

Description The controller is supplying current to the traction motors while sensing one or both of the traction motors is not turning. Symptom No truck movement while depressing the accelerator pedal. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Wheel is in a hole and the truck cannot move. • Brake coil has not released the brake disk. • Mechanical failure of one or both of the traction motors. • Use the dash display diagnostics to check operation of traction motor encoder. • Check for 12 volts at encoder between wires 75 and 76. • Ensure all wiring connections between the encoder harness and the traction motor are tight. • Check for continuity of all wiring between the encoder and the traction controller. • Check for any shorted condition from pins C11, C12, C22, or C23 at the traction controller to the truck frame. • • Ensure the wiring to the encoder is correct. See the section Diagrams 8000 SRM 1081. • Disconnect the 6 pin connector at the traction motor and measure the resistance between any combination of pins 1, 2, 5, and 6. The resistance should be at least 1 megohm.

90

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

250R

RIGHT ROTOR LOCKED

Yes

Traction

Description The controller is supplying current to the traction motors while sensing one or both of the traction motors is not turning. Symptom No truck movement while depressing the accelerator pedal. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Wheel is in a hole and the truck cannot move. • Brake coil has not released the brake disk. • Mechanical failure of one or both of the traction motors. • Use the dash display diagnostics to check operation of traction motor encoder. • Check for 12 volts at encoder between wires 83 and 84. • Ensure all wiring connections between the encoder harness and the traction motor are tight. • Check for continuity of all wiring between the encoder and the traction controller. • Check for any shorted condition from pins C1, C2, C13, or C14 at the traction controller to the truck frame. • • Ensure the wiring to the encoder is correct. See the section Diagrams 8000 SRM 1081. • Disconnect the 6 pin connector at the traction motor and measure the resistance between any combination of pins 1, 2, 5, and 6. The resistance should be at least 1 megohm.

91

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

260

PUMP MOTOR VOLTAGE LOW

Yes

Transistor Lift

Description Incorrect voltage on pump motor. Symptom No lift operation. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Wrong voltage battery installed in truck. Ensure battery voltage matches voltage shown on truck nameplate. • Wrong voltage parameter selection. Ensure parameter setting matches voltage shown on truck nameplate. Check parameter setting using the dash display. • Check for any shorted condition from P+ or P- to the truck frame. • Check for any shorted condition between P- and B-. • Check P+ and P- connections are tight at the controller and the pump motor.

92

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

270

LIFT/LOWER LEVER ERROR

Yes

Electro-hydraulic

Description Error in signal from the lift/lower lever assembly. Symptom No lift/lower operation. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check all wiring connections between the hydraulic lever console and the hydraulic controller are tight and secure. • Check for 12 volts at pin 1 on the hydraulic lever console. Check for 12 volts at pin B10 on the valve driver module. • Replace the lift/lower lever PC board.

93

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

271

TILT LEVER ERROR

Yes

Electro-hydraulic

Description Error in the signal from the tilt lever. Symptom No mast tilt operation. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check all wiring connections between the hydraulic lever console and the hydraulic controller are tight and secure. • Check for 12 volts at pin 1 on the hydraulic lever console. Check for 12 volts at pin B10 on the valve driver module. • Replace the tilt lever PC board.

94

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

272

3RD FUNCTION LEVER ERROR

Yes

Electro-hydraulic

Description Error in the signal from the sideshift lever. Symptom No carriage sideshift operation. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check all wiring connections between the hydraulic lever console and the hydraulic controller are tight and secure. • Check for 12 volts at pin 1 on the hydraulic lever console. Check for 12 volts at pin B10 on the valve driver module. • If the truck is not equipped with 3rd. function, make sure 3rd function parameter is set at 3. • Replace the sideshift lever PC board.

95

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

273

4TH FUNCTION LEVER ERROR

Yes

Electro-hydraulic

Description Error in the signal from the auxiliary lever. Symptom No operation of the auxiliary hydraulic function. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check all wiring connections between the hydraulic lever console and the hydraulic controller are tight and secure. • If the truck is not equipped with 4th function, make sure 4th function parameter is set at 3. • Check for 12 volts at pin 1 on the hydraulic lever console. Check for 12 volts at pin B10 on the valve driver module. • Replace the auxiliary lever PC board.

96

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

275

VALVE CONTROLLER FAULT

Yes

Electro-hydraulic

Description Internal failure of the valve driver module. Symptom No operation of the electro-hydraulic functions. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Recycle key switch from OFF to ON. • Check all pins at the valve controller connector are tight and secure. • Replace the valve driver module.

97

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

276

LIFT/LOWER EV DRIVER SHORTED

Yes

Electro-hydraulic

Description Lift/lower driver in the valve driver module is shorted. Symptom No lift/lower operation. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Recycle key switch. • Disconnect connector "C" from EV. Check all wires for shorts to B-, the truck frame, or between wires. • Check resistance of coils: Resistance should read approximately 19 ohms at 25 C (77 F).

EV = Electro-hydraulic valve driver module.

98

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

277

4TH FUNCTION EV DRIVER SHORTED

Yes

Electro-hydraulic

Description Auxiliary driver in the valve driver module is shorted. Symptom No operation of the auxiliary hydraulic function. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Recycle key switch to clear fault. • Disconnect connector "C" from EV. Check all wires for shorts to B-, the truck frame, or between wires. • Check resistance of coils: Resistance should read approximately 19 ohms at 25 C (77 F).

EV = Electro-hydraulic valve driver module.

99

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

279

TILT EV DRIVER SHORTED

Yes

Electro-hydraulic

Description Tilt driver in the valve driver module is shorted. Symptom No tilt function operation. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Recycle key switch to clear fault. • Disconnect connector "C" from EV. Check all wires for shorts to B-, the truck frame, or between wires. • Check resistance of coils: Resistance should read approximately 19 ohms at 25 C (77 F).

EV = Electro-hydraulic valve driver module.

100

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

280

3RD FUNCTION EV DRIVER SHORTED

Yes

Electro-hydraulic

Description The sideshift function driver in the valve driver module is shorted. Symptom No sideshift function operation. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Recycle key switch to clear fault. • Disconnect connector "C" from EV. Check all wires for shorts to B-, the truck frame, or between wires. • Check resistance of coils: Resistance should read approximately 19 ohms at 25 C (77 F).

EV = Electro-hydraulic valve driver module.

101

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

281

EV 9 DRIVER SHORTED

Yes

Electro-hydraulic

Description Single EVP driver is shorted. Symptom

Probable Causes and Test Procedures This spare output is not used. • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Recycle key switch to clear fault. • Disconnect connector "C" from EV. Check all wires for shorts to B-, the truck frame, or between wires.

EV = Electro-hydraulic valve driver module. EVP = Electro-hydraulic proportional valve driver.

102

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

282

SELECTOR EV DRIVER SHORTED

Yes

Electro-hydraulic

Description On/off EV driver is shorted. Symptom

Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Recycle key switch to clear fault. • Disconnect connector "C" from EV. Check all wires for shorts to B-, the truck frame, or between wires. • Check resistance of coils: Resistance should read approximately 19 ohms at 25 C (77 F).

EV = Electro-hydraulic valve driver module.

103

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

283

SELECTOR EV COIL SHORTED

Yes

Electro-hydraulic

Description One of the electro-hydraulic valve coils is shorted. Symptom One of the hydraulic functions will not operate. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Recycle key switch to clear fault. • Disconnect connector "C" from EV. Check all wires for shorts to B-, the truck frame, or between wires. • Check resistance of coils: Resistance should read approximately 19 ohms at 25 C (77 F).

EV = Electro-hydraulic valve driver module.

104

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

289

EV CONTROLLER LOW VOLTAGE

Yes

Electro-hydraulic

Description Voltage supply to the valve driver control module is low. Symptom No operation of the electro-hydraulic functions. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check for battery voltage at pins B1 and B2 with key switch closed. • Check that all connections are secure.

EV = Electro-hydraulic valve driver module.

105

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

292

WRONG BATTERY SET IN EV CONTROLLER

Yes

Electro-hydraulic

Description Incorrect battery selection parameter in the valve driver module. Symptom No operation of hydraulic system. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Ensure battery voltage matches voltage shown on the lift truck nameplate. Install correct voltage battery in the lift truck. • Ensure battery parameter setting matches voltage shown on the lift truck nameplate. Use dash display to change battery parameter.

EV = Electro-hydraulic valve driver module.

106

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

294

INTERLOCK SWITCH

No

Hydraulic

Description Message is displayed when an interlocked hydraulic function is requested without activating the interlock switch. Symptom No operation of the requested interlocked hydraulic function. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Check interlock switch on the ILM; replace as necessary.

107

Troubleshooting

2200 SRM 1087

Status Code

Premium Display Message

Memory Recall

Circuit

295

NO LO LIFT SWITCH INPUT

Yes

Hydraulics

Description Message is displayed when the hi-lift switch is closed and the lo-lift switch is open. Symptom Lift will only operate at low speed. Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • Check that the battery disconnect switch, the key switch, and the main contactor contacts are in the correct position and properly making contact. • Use dash display diagnostics to check for correct operation of the lo-lift switch. • Check switch for correct operation. • Check for correct switch adjustment. See the section Electrical System 2200 SRM 1078 for adjustment procedure. • Check wiring to switch for loose connections or broken wires.

108

2200 SRM 1087

Troubleshooting

Status Code

Premium Display Message

Memory Recall

Circuit

299

WRONG CONFIGURATION

Yes

Traction

Description

Symptom

Probable Causes and Test Procedures • Ensure all fuses are properly seated and tight in the fuse holders. • Ensure all wiring connections are tight and secure at the fuse panel, key switch, and the battery disconnect switch. • • Recycle key switch. • Check CAN wiring for loose connections at connectors or broken wires.

109

Troubleshooting

2200 SRM 1087

CONTROLLER CONNECTOR PIN OUTS

Table 6. Connector C (Continued)

Table 5. Connector A Pin A1

Wire Number CANH

Wire Number

Function

C15

70

Steering Potentiometer B

C16

72

Steering Potentiometer Positive (+5V/+12V)

C17

71

Steering Potentiometer Wiper Input

C18

104

Brake Potentiometer Wipe Input

C19

103

B

C20

27

Accelerator Potentiometer B

C21

29

Traction Potentiometer Wiper Input

C22

77

Left Motor Encoder Phase B

Function High Level CANbus

A2 A3 A4

Pin

CANL-OUT

Low Level CANbus

A6

CANL

Low Level CANbus

A7

CANH-OUT

High Level CANbus

A5

A8

Table 6. Connector C Pin

Wire Number

Function

C1

83

Right Motor Encoder Positive (+5V/+12V)

C23

78

Left Motor Encoder Phase A

C2

84

Right Motor Encoder B

C24

82

Right Motor Temp Sensor B

C3

10

B+ from Key Switch

C25

81

C4

110

B+ to Switches

Right Motor Temp Sensor Input Signal

C5

101

Seat Switch Input

C26

23

Main Contactor B

C6

6

Forward Switch Input

C27

24

Main Contactor B+

C7

8

Reverse Switch Input

C28

50

Parking Brake Coil B

C8

15

Start Switch Input

C29

51

Parking Brake Coil B+

C9

92

Brake Pedal Switch Input

C30

88

Auxiliary B+

C31

87

Auxiliary B

C10

94

Hydraulic Function Input (Contactor Hydraulic Only)

C32 C33

28

Traction Potentiometer Positive (+5V/+12V)

B

C11

75

Left Motor Encoder Positive (+5V/+12V)

C34

79

Left Traction Motor Temp Sensor B

C12

76

Left Motor Encoder B

C35

80

C13

85

Right Motor Encoder Phase B

Left Traction Motor Temp Sensor Input Signal

C14

86

Right Motor Encoder Phase A

110

2200 SRM 1087

Troubleshooting

Table 7. Connector D - Standard Model Pin

Wire Number

Function

D2

113

High Speed Lift Switch Input

D3

98

Low Speed Lift Switch Input

D4

114

Tilt Speed Prox Switch Input

D5

210

B+ for Hydraulic Switches

D6

97

4th Function Speed Switch Input

D7

93

Sideshift Switch Input

D8

95

Tilt Switch Input

Table 8. Connector D - Premium Model (Continued) Pin

D1

Wire Number

Function

D11 D12 D13 D14

VALVE DRIVER MODULE (ELECTRO-HYDRAULIC VALVE OPTION) Table 9. Connector B Pin

Wire Number

B1

10-1

Key Switch Input B+

B2

10-1

Key Switch Input B+

B3

130

Battery Negative

B4

CANL-2

B5

OPEN

B6

OPEN

B7

OPEN

B8

OPEN

B9

OPEN

B10

74

D1

B11

OPEN

D2

B12

OPEN

D3

B13

CANH-2

B14

OPEN

D9 D10 D11 D12 D13 D14

Table 8. Connector D - Premium Model Pin

Wire Number

Function

D4

114

Tilt Speed Prox Switch Input

D5

210

B+ for Hydraulic Switches

D6

D9 D10

CAN Low Input Signal

12V Supply to Lever Module

CAN High Input Signal

Table 10. Connector C Pin

Wire Number

Function

C1

53

Negative for Lowering Proportional Valve

C2

52

Positive for Lift and Lower Proportional Valves

D7 D8

Function

111

Troubleshooting

2200 SRM 1087

Table 10. Connector C (Continued)

Table 10. Connector C (Continued) Pin

Wire Number

Function

C3

54

Negative for Lift Proportional Valve

C4

56

Negative for Auxiliary IN Proportional Valve

C5

55

Positive for Auxiliary Proportional Values

C6

57

Negative for Auxiliary OUT Proportional Valve

C7

59

C8

58

C14 C15

63 60

C16

64

C17

66

C18

OPEN

C19

OPEN

C20

OPEN

C21

OPEN

112

Battery Negative

HYDRAULIC LEVER CONSOLE (ELECTRO-HYDRAULIC OPTION ONLY)

74

12V Supply from Valve Driver Module

Positive Voltage Supply for Tilt Proportional Valves

2

CANH_OUT1

3

130

4

CANL_OUT1

Negative for Tilt Auxiliary Selector Valve

61

130

1

67

C13

C23

Negative for Tilt UP Proportional Valve

C10

62

OPEN

Function

Negative for Load Hold Valve

C12

C22

Function

Wire Number

65

OPEN

Wire Number

Pin

C9

C11

Pin

CANbus High Battery Negative CANbus Low

DASH DISPLAY Pin

Wire Number

A1

10-1B

Key Switch Input B+

Negative for Sideshift Right Proportional Valve

A2

110-1

Positive Supply to Indicators

A3

130F

Battery Negative B

Positive for Sideshift Right and Left Proportional Valves

A4

130G

Battery Negative B

A5

107

Negative for Sideshift Left Proportional Valve

Lift Motor Brush Wear Indicator Input

A6

102

Negative for Tilt Down Proportional Valve

Negative for Pump Motor Temp Sensor

A7

CANL-1

A8

OPEN

A9

90

Negative for Hydraulic Oil Lever Sensor

A10

91

Positive for Brake Fluid Level Switch

A11

96

Negative for Auxiliary Switch

A12

50G

Positive for Lift Hold Valve Positive for Tilt Auxiliary Selector Valve

Function

CANbus Low

Parking Brake Coil Input

2200 SRM 1087

Troubleshooting

Pin

Wire Number

Function

A13

50F

A14

OPEN

A15

OPEN

A16

47B

Steering Encoder Input

SYSTEM LOGIC DIAGRAMS

A17

12A

Battery Positive B+

A18

130P

Battery negative B

A19

OPEN

The system logic diagrams for the economy, standard, and premium truck models may be able to assist in troubleshooting. See Figure 18, Figure 19, and Figure 20.

A20

26

Parking Brake Coil Input

Pin

Wire Number

A21

OPEN

A22

CANH-1

A23

OPEN

Function

CANbus High

Positive for Reverse Alarm

Figure 18. Logic Diagram - Economy

113

Troubleshooting

2200 SRM 1087

Figure 19. Logic Diagram - Standard

114

2200 SRM 1087

Troubleshooting

Figure 20. Logic Diagram - Premium

115

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

116

TECHNICAL PUBLICATIONS 2200 SRM 1087

8/05 (2/05) Printed in United Kingdom